Forming Apparatus and System

ABSTRACT

A forming system is provided for retaining a conformable material. The conformable material is, in one embodiment, concrete. The forming system includes one or more forming members, some comprising at least two panels connected in spaced relation so as to define a substantially linear passageway adapted to retain a first supply of concrete. In other embodiments, the forming member may comprise one or more panels forming various configurations so as to define substantially non-linear passageways or an end forming member to retain a conformable or settable material such as concrete which hardens in place. Each of at least two panels of the forming member further preferably comprises at least one interconnectable end defining an interconnectable element. The at least one interconnectable end, in some embodiments, forms an interengageable slot with the interconnectable element adapted to be interconnectable with at least one other structure. The one other structure, in some embodiments, comprises one or more forming members being configured similarly. Additionally, the at least two panels, in one embodiment, are preferably adapted to be disconnectable after use to subsequently receive a second supply of conformable material.

FIELD OF THE INVENTION

The present invention relates generally to an apparatus, system andmethod for forming a material, and more particularly, to an apparatus,system and method for forming a conformable material, such as, forexample, concrete.

BACKGROUND OF THE INVENTION

In the construction industry, numerous techniques, methods, and devicesare available for building structures out of a variety of materialsusing different structural systems. Some construction methods use, forexample, “wood frame walls”; others use “concrete block walls.” Many ofthese structural systems and construction methods, however, requiretime-consuming, heavy and cumbersome “component-by-component”construction—with relatively difficult to handle components (e.g.,boards, concrete blocks, etc.). Moreover, these components must besecured together in some manner (e.g., nails, mortar, etc.) andtypically require skilled, experienced labor.

Building a “concrete block wall,” for example, requires specializedmasonry skills to properly handle and align blocks and apply mortar tojoin and secure the concrete blocks so as to form a uniform, verticallyand horizontally aligned block wall; such specialized labor adds to thecost and time of a construction project.

In contrast to a “concrete block wall,” a poured concrete wall in manyinstances produces a stronger, longer-lasting wall, which provides moredesirable sound and weather-resistant qualities. A poured concrete wallis effectively one solid structure while a “concrete block wall”—whichin effect requires handling each cumbersome concrete block—isconstructed, as noted, block-by-block with mortar for example. A solidlyconstructed poured concrete home would also provide durability and manyother advantages typically needed where there is exposure to hurricanes,tornados or other harsh weather conditions. Additionally, unlike a “woodframe wall,” such a structure also is resistant to termites.

Various methods and devices for building concrete walls include, forexample, first erecting forms usually consisting of several parallelwalls which form a space therebetween for receiving and holdingconcrete. Such devices also usually require substantial alignment andbracing prior to pouring concrete. Once the poured concrete wall hasfully cured, the forms may be removed.

Unfortunately, many of these processes and devices have drawbacks inthat they utilize forming walls, complicated shoring reinforcements andalignment devices that are unwieldy, heavy, and require extensive effortand expense to transport to and from a construction site. Due to theirweight and bulkiness, many of these form devices require large equipmentto handle and position them during the set up and forming process—thusmaking them time-consuming and cumbersome to use prior to actually beingable to pour concrete. Moreover, such hefty and awkward devices leaveeven fewer options for less-muscle bound individuals or elderly personswith certain ailments who desire—on their own—to set up and handle formsso as to form up some structure, building or the like.

There are also other types of forming systems—which are not reusable andremain permanently affixed to the building. Such systems typicallyinclude insulating features and also incorporate insulating materialsand multi-layered forms having built in insulation. Unfortunately, thesesystems may be unnecessarily labor-intensive and may be too complex toefficiently use for many building structures thus driving up the effortand cost of a construction project. And, again, they can requirespecialized labor or training.

In addition, although some multiple form devices are reusable, theseforms are not easily and quickly removable—especially when multipleadjacent forms are interconnected next to and/or stacked on one anotherusing time-consuming, threaded fasteners.

The following U.S. patents disclose a variety of systems and devices,which have attempted to resolve at least some of the above problems:

U.S. Pat. No. 6,405,505 to Alberti, entitled “Modular interlock wallform,” sets forth a modular interlock wall form for providing a sturdywall structure that is easily assembled and disassembled. The modularinterlock wall form includes a base frame for resting on a surface, andwhich includes a pair of elongate base rails extending in thelongitudinal direction of the base frame. The base rails are laterallyspaced, and at least one lateral member extends laterally across thebase rails. The lateral member has a fascia support portion extendingsubstantially perpendicular to an axis of a central portion of thelateral member. A face panel is provided for forming a face of themodular interlock wall form. The face panel has opposite surfaces and aperimeter edge. The perimeter edge comprises opposite end edges andopposite first and second edges. The first edge is adapted for beingoriented downwardly and the second edge is adapted for being orientedupwardly.

The second edge has a tongue extending along the length of the secondedge with at least one pocket recessed in the tongue. The first edge hasa groove extending along the length of the first edge, and is alsoadapted to receive one of the base rails of the base frame and isadapted to receive the tongue of the first edge. The end edges also havegrooves formed therein. A linking frame is provided for linking spacedtiers of face panels together. The linking frame comprises a pair oflinking members extending in the longitudinal direction of the linkingframe, and at least one spanning member extending laterally across thelinking members. The spanning member is coupled to each of the linkingmembers.

U.S. Pat. No. 6,363,683 to Moore, Jr., entitled “Insulated concreteform,” discloses an insulated concrete structure including at least onelongitudinally-extending side panel and at least one web memberpartially disposed within the side panel. The web member extends fromadjacent the external side of the side panel through and out of theinterior surface of the side panel. The first embodiment of the presentinvention uses opposed side panels that form a cavity therebetween intowhich concrete is poured and cured. The second embodiment uses a singleside panel as a form, onto which concrete is poured. Once the concretecures on the single side panel, it is used as a tilt-up wall, floor, orroof panel.

U.S. Pat. No. 6,321,496 to Martin, Jr., entitled “Insulated formassembly for a poured concrete wall,” is directed to an insulated formassembly for a poured concrete wall which includes a plurality ofinsulated forms. Each insulated form includes two generally planaropposing panels, and a plurality of interior segments interconnectingthe panels and defining a plurality of passageways. Each panel includesa vertically extending attachment channel and an attachment memberdisposed within the attachment channel.

U.S. Pat. No. 6,178,711 to Laird et al., entitled “Compactly-shippedsite-assembled concrete forms for producing variable-widthinsulated-sidewall fastener-receiving building walls,” sets forthgenerally large, typically eight feet by two inches by ten or sixteen ortwenty-four inches, sidewalls for modular concrete forms which areeasily, efficiently and economically produced by cutting and by routingsheet-type polymeric material, preferably polyurethane or expandedpolystyrene foam. Metal connecting members are produced in standardsizes by cutting and bending sheet steel and/or wire. The sidewalls andconnecting members are transported to a building site tightly andcompactly in pieces, and then flexibly assembled into precision wallforms at the site with good efficiency at any scale. The wall forms soassembled define a cavity into which reinforcing steel rod, electricaland/or communications conduit, plumbing, etc., may be entered. Concreteis poured into the cavity to create a wall having the form sidewalls asits permanent surfaces. These surfaces have and present visibleregularly-spaced sheet steel strips suitable to receive and to engagesheet metal screws for mounting anything, including more sheet-typeconstruction materials such as wallboard or paneling, to the wall. Thethickness of the concrete wall is predetermined by the dimensions of itsmetal sidewall-connecting members, and may easily be varied such asduring the fabrication of lower to upper wall courses of a multi-storybuilding.

U.S. Pat. No. 5,735,093 to Grutsch, Jr., entitled “Concrete formworkwith backing plates,” is directed to foam forms for use in making aconcrete wall that are disclosed together with a method of making theforms. The forms are stackable to form a cavity that receives theconcrete. Each form has two identical panels. The panels are moldedseparately by first placing a structure, consisting of backing platesthat will be along one side of the mold, connecting members that will bealong the opposite side of the mold and an apparatus that connects thebacking plates to the connecting members, in the mold. The mold is thenfilled with foam which cures and produces a panel with the backingplates, connecting members and apparatus molded into the panel. Themolded panels are then shipped to the job site where the forms areassembled. Each form is assembled as follows: The connecting members onone panel are interconnected, by tieing means, to the connecting memberson a second panel to provide a form.

U.S. Pat. No. 4,936,540 to Boeshart, entitled “Tie for concrete forms,”sets forth a tie for concrete forms which includes an elongated strapwith opposing first and second ends. The strap has an upwardlyprojecting intermediate portion which prevents the movement of formpanels inwardly on one end of the strap. A notch in the first end of thestrap receives a waler to hold form panel from moving outwardly alongthe strap. A fixed plate on the second end of the strap holds a formpanel from moving outwardly along the strap. Beveled ends allow thestrap to be forced through a polystyrene panel without the need forforming an aperture in the panel prior to insertion of the tie. Atubular spacer may be utilized on intermittent ties to prevent inwardmovement of the form panels. The spacer has a notch cut therein to allowconcrete to flow within the spacer and around the tie.

U.S. Pat. No. 4,726,560 to Dotson, entitled “Concrete form tieassembly,” sets forth a concrete form tie assembly in which the tie rodis formed from a high tensile strength flexible wire member, with thesleeve being formed of a flexible or yieldable material. A short sleevemember is inserted into the spacer sleeve adjacent one end with washermembers on opposite ends thereof for retaining on the tie rod memberwhich is provided with spaced protrusions for coaction with the washmembers, the tube and washer assembly serving to rigidify the assemblyfor assisting in insertion and removal of the tie rod and sleeve as aunit. The leading end of the tube and washer assembly may be providedwith a conical end to act as a guide. The ends of the tie rod member areenlarged, such as by welding head members thereto, the head membersbeing configured for coaction with conventional hairpin or snap tiewedge members.

U.S. Pat. No. 3,927,857 to Lovisa et al., entitled “Reusable tieassembly for concrete forms,” discloses a retractable, removable andreusable tie assembly for concrete forms which includes a single tie rodhaving a pipe slidably mounted on one end thereof and an internalspreader system interposed between its ends for spacing the forms apredetermined distance apart during concrete pour. The internal spreadersystem includes a loose cone adapted to be threadedly engaged with oneend of the pipe and a rubber tube adapted to sealingly engage with thiscone as well as a second cone secured to the other end of the tube. Thisconnection includes a ferrule and insert engageable with a steel washerembedded in the secured cone. The insert is interiorly threaded tofacilitate removal of the cone and attached rubber tube after the formshave been stripped. Interengaging surfaces of threaded insert and therod assure the proper location of the internal spreader system after thefirst and closing form have been erected. Wedges at each end of the tieassembly complete the erection of the forms. After the concrete has beenformed and satisfactorily hardened the forms are then stripped. Towardsthis end, the rod and associated pipe are removed by initiallyuncoupling one or both of the wedges and then unscrewing the pipe fromits associated cone. Thereafter the loose cone may be removed with asuitable tool or bolt with a thread mating with the internal thread ofthis cone. The other cone and secured tube may then be removed by meansof a second tool or bolt having a threaded portion mating with that ofthe thread of the insert. The tie assembly may then be reused wheredesired.

U.S. Pat. No. 3,858,993 to Lovisa et al., entitled “Reusable tieassembly for concrete forms,” is directed to a retractable, removableand reusable tie assembly for concrete forms which includes a single tierod, and an internal spreader and spacing system which includes a sleevemeans, the spreader system having built-in provisions for internalspreading and spacing of forms in such a manner as to permit the tie rodto be partially withdrawn on one side of the form facilitating theinstallation of the closing form, on the opposite side, and then to beinserted to engage and lock with the internal spreader system, thuskeeping the two adjacent sides of the forms in a definite predeterminedposition apart during the concrete pour, then to be removed undamagedfrom the hardened concrete prior to dismantling of the forms, leavingthe internal spreader in the concrete to be removed after stripping ofthe forms without damaging the internal spreader.

In addition, several examples of some publications related to buildingconstruction methods and devices include the following:

Concrete Homes, October/November 2006, (page 7), shown under the articleentitled, “Fox Blocks T-Block now available in 6- and 8-inch sizes”offered through Airlite Plastics.

Concrete Homes, June/July 2006, (page 37), shown under the articleentitled, “COMPLEXITY captures CFA award” offered through suppliers forBalmer Brothers Concrete Work, Inc.

Concrete Homes House Plans—2004, (page 9), shown under the articleentitled “COUNTING ON CONCRETE” related to, for example, “InsulatingConcrete Forms” (page 12), “Removable forms” (page 13), “Precastconcrete panels” (page 14), etc.

http://www.eere.energy.gov/buildings/info/components/envelope/foundation.html(visited Apr. 1, 2007), entitled “Building Technologies Program.”

http://www.cfawalls.org/products/nat_suppliers/index.htm (visited Apr.1, 2007), entitled “CFN National Suppliers.”

http://www.cfawalls.org/products/nat_suppliers/wallties.html (visitedApr. 1, 2007), entitled “Wall-ties & Forms, Inc.”

http://www.wallties.com/concrete_forms.htm (visited Apr. 1, 2007),entitled “Concrete Form Accessories” related to, for example, “GangAdapters,” “Pins and Wedges,” “Waler Brackets,” Wall Ties,” “LaydownApplications,” “Blockouts/Blockdowns,” “Special Application Hardware,”“Wall Thickness Change,” “Concrete Form Stacking,” etc.

http://www.integraspec.com (visited Feb. 26, 2007), entitled “InsulatingConcrete Forms—IntegraSpec®”

http://www.integraspec.com/product.html (visited Feb. 26, 2007), relatedto, for example, Phil-Insul Corp Product Descriptions for spacers,panels, etc.

However, in view of the foregoing, there still remains a need for aforming system, method and apparatus including a simple-to-manufacture,configurable forming member which is easy to set up, stack, and removeafter the concrete wall is poured and has cured and which has a simple,reusable configuration which is adapted to be more easily and quicklyinstalled, without requiring specialized and experienced skilled labor,so as to enable a person without such specialized training or educationto form and build a wall.

Those of skill in the art will appreciate the present invention whichaddresses the above problems and other significant problems, thesolutions to which are discussed hereinafter.

SUMMARY OF THE INVENTION

It is one possible objective of one possible embodiment of the presentinvention to provide an improved method and apparatus for forming andretaining a material such as for example, concrete, to build variousstructures or for forming other materials.

These and other objectives, features, and advantages of embodiments ofthe present invention will become apparent from the drawings, thedescriptions given herein, and the appended claims. However, it will beunderstood that the above-noted objectives of various embodiments areintended only as an aid in understanding aspects of the embodiments, andare not intended to limit the embodiments of the invention in any way,and therefore do not form a comprehensive or restrictive list ofobjectives, and/or features, and/or advantages of the variousembodiments of the invention.

Accordingly, in one possible embodiment, an apparatus is provided forretaining a conformable material, including at least a forming membercomprising at least two panels connected in spaced relation so as todefine a passageway adapted to retain a first supply of conformablematerial which hardens in place, such as, in one embodiment, concrete.Each of the at least two panels of the forming member further preferablycomprises at least one interconnectable end defining an interconnectableelement. The at least one interconnectable end, in some embodiments,forms an interengageable slot with the interconnectable element adaptedto be interconnectable with at least one other structure. The one otherstructure in a preferred embodiment comprises one or more formingmembers being configured similarly. Additionally, the at least twopanels, in one embodiment, are adapted to be disconnectable after use tosubsequently receive a second supply of conformable material, whichhardens in place.

Another possible embodiment further comprises an engagement memberforming an interconnection slot. The engagement member is preferablyreceivable by both an interengageable slot of an interconnectableelement of a given forming member and an interengageable slot of aninterconnectable element of at least one other forming member, whereinthe given forming member and the at least one other forming member maybe interconnected.

In a possible embodiment, a plurality of forming members are selectivelyconfigurable and interconnectable in a desired arrangement such that atleast a portion of an enclosure may be constructed from the formingmembers with the forming members defining a plurality of passageways forretaining the conformable material.

In another possible embodiment, each of the at least two panels furthercomprises a base flange and a support member. In one embodiment, each ofthe support members of a given forming member cooperate to alignablyreceive the base flanges of the at least one other forming member whenstacked on the given forming member. In this way, a plurality of stackedforming members would define a wall of forming members defining aplurality of vertically-extending passageways to retain the conformablematerial. In another embodiment, each of the support members furtherincludes at least a support flange and a guide flange. The guide flangesof the support members are preferably disposed in opposing spacedrelation.

In other embodiments, at least two panels are configured so as to definea passageway having a substantially ninety-degree configuration adaptedto retain a conformable material. While in various other embodiments, atleast three panels are configured so as to define a passageway having asubstantially T-shaped configuration adapted for retaining a conformablematerial.

Another embodiment further comprises a contour member being mountablewithin the passageway with the contour member having a selected surfacecontour facing the interior of the passageway.

In another possible embodiment, a forming system is provided forretaining a material with the forming system including at least aforming member comprising at least two panels in spaced relation so asto define a passageway adapted to retain a first supply of settablematerial. Each of the at feast two panels further comprises a baseflange extending from each panel away from the passageway, and a supportmember on an opposite side from the base flange, with the support memberextending away from the passageway. The support member further comprisesa guide member adapted to alignably receive a base flange of anotherforming member when stacked on the forming member. In this way, the atleast two panels are alignable with at least two panels of said anotherforming panel. The at least two panels are preferably, in someembodiments, adapted to be disconnectable after retaining the firstsupply of settable material for subsequently receiving a second supplyof settable material. In one possible embodiment, the each of the atleast two panels comprises at least one interconnectable end defining asecurable flange with the securable flange adapted to beinterconnectable with a corresponding securable flange of anotherforming member. The forming system preferably comprises, in someembodiment, an engagement component adapted to interconnect a securableflange of the forming member, with a corresponding securable flange ofanother forming member. In other embodiments, each of the at least twopanels further comprises at least one interconnectable end defining aninterconnectable element forming an interengageable slot, with theinterconnectable element adapted to be interconnectable with at leastone other forming member. In such an embodiment, the forming systemfurther comprises an engagement member forming an interconnection slot,with the engagement member receivable by both an interengageable slot ofan interconnectable element of a given forming member and aninterengageable slot of an interconnectable element of the at least oneother forming member. In this way, the given forming member and the atleast one other forming member may be interconnected. Moreover, aplurality of forming members having selected configurations may beinterconnected and stacked, and a plurality of walls of forming membersmay be interconnected so as to form at least a portion of an enclosure.In other embodiments, the forming system also further comprising atleast one spacer connector comprising a spacer element and a reusableconnector, with the at least one spacer connector adapted to releaseablyconnect in spaced relation each of the at least two panels of at leastone of the forming members. In another embodiment, the at least twopanels may be configured so as to define a passageway having asubstantially non-linear configuration adapted for retaining a settablematerial. In other embodiments, at least three panels may be configuredso as to define a passageway having a substantially T-shapedconfiguration adapted for retaining a settable material.

In another possible embodiment, a unitary structure reusably combinablewith other unitary structures to create forms to receive settablematerial may be provided, which includes at least a panel, at least oneintegrally formed interconnectable end defining a securable element, abase flange integrally formed at a first peripheral edge of the panel,and a support member integrally formed at a second peripheral edge ofthe panel. Preferably, the panel, at least one integrally formedinterconnectable end, base flange, and support member are of one-piececonstruction and comprise at least one of sheet metal or plastic.

BRIEF DESCRIPTION OF THE DRAWINGS

For a further understanding of the nature and objects of variousembodiments of the present invention, reference should be had to thefollowing detailed description, taken in conjunction with theaccompanying drawings, and wherein:

FIG. 1 is a perspective view of one possible embodiment of the inventionshowing a forming member having two panels connected in spaced relationso as to define a passageway for receiving a material.

FIG. 2 is a perspective view of one possible embodiment of the inventionshowing a forming member having two panels in spaced relation without aspacer connector.

FIG. 3 is a perspective view showing a spacer element and a connector ofone possible embodiment of the invention.

FIG. 4 is a perspective view of one possible embodiment of the inventionshowing an engagement member.

FIG. 5 is a perspective view of one possible embodiment of the inventionshowing a plurality of forming members interconnected by a plurality ofengagement members and stacked on one another so as to define a wall offorming members.

FIG. 6A is a perspective view of another possible embodiment of theinvention showing a forming member having two panels connected in spacedrelation so as to define a passageway for receiving a material.

FIG. 6B is a top view of one possible embodiment of the inventionshowing a forming member.

FIG. 6C is a plan view of one possible embodiment of the inventionshowing a portion of the forming member integrally formed from a unitarystructure.

FIG. 7 is a perspective view of one possible embodiment of the inventionshowing a forming member configured so as to define a passageway havinga substantially non-linear configuration.

FIG. 8 is a perspective view of one possible embodiment of the inventionshowing a forming member configured so as to define a passageway havinga substantially T-shaped configuration.

FIG. 9 is a perspective view of one possible embodiment of the inventionshowing an end forming member configured to close off a portion of apassageway.

FIG. 10 is a perspective view of one possible embodiment of theinvention showing an end panel configured to close off a portion of apassageway, and further showing one possible embodiment ofinterconnectable ends with each interconnectable end havinginterengagable flanges.

FIG. 11 is a perspective view of one possible embodiment of theinvention showing a form object preferably removably captured within apassageway between the panels of two stacked forming members.

FIG. 12 is a perspective view of one possible embodiment of theinvention showing a contour member.

FIG. 13 is a perspective view of one possible embodiment of theinvention showing an example of another contour member.

FIG. 14 is an elevational side view of one possible embodiment of theinvention showing a base flange of one forming member secured to asupport member of another forming member by a retaining member.

FIG. 15 is an elevational side view of one possible embodiment of theinvention showing a support connector having a portion insertablethrough a spacer element captured within a formed wall.

While the present invention will be described in connection with variousexample embodiments, it will be understood that it is not intended tolimit the invention to those embodiments. On the contrary, it isintended to cover all alternatives, modifications, and equivalentsincluded within the spirit of the invention.

GENERAL DESCRIPTION OF EMBODIMENTS OF THE INVENTION

One possible preferred embodiment of the present invention effectivelyprovides a system of easy to manufacture reusable forming members thatcan be used by a person (with or without specialized skills) toinexpensively and quickly build, for example, a concrete building orstructure of various desired dimensions using locally available personsand materials. The system is especially ideal for use in regions orcountries where there is a lack of skilled construction workers and aneed for housing.

The same set of relatively inexpensive forms can be used—and reused—tobuild many types of houses or buildings having a variety of layouts anddesigns. The system is also ideal for implementing the “do-it-yourself”projects of homeowners, landowners, and the like who have some time, butlittle actual construction experience, and who wish to save money whileeffectively and quickly building a desired structure, building, shed,retaining wall, footing, or the like—or tying into or replacing anexisting wooden wall or other structure. A possible embodiment of thepresent invention may comprise quite lightweight forming members whichare easy to set up, stack, remove, and reuse after a concrete wall hasbeen poured and has cured.

Now referring to all of the drawings, and more particularly to FIG. 1,there is shown one possible embodiment of the present inventioncomprising a forming member 10 adapted for retaining a material. Formingmember 10 may preferably include at least two panels 12, 14 connected inspaced relation so as to define a passageway 16 adapted for retaining amaterial which is ideally conformable. In one possible embodiment, thepassageway 16 may be adapted to retain a first supply of conformablematerial, which hardens in place. The conformable material may includeconcrete or any other material that can be poured, for example, intopassageway 16 between the panels 12, 14.

If concrete is not available, then locally available materials such asmud, straw, shells, and the like may also be utilized. Other materialssuch as foam plastic, other fluid substances or any pourable medium maybe utilized. Rebar or reinforcement wires or fibers may also be easilyinserted into the pourable medium, or prior to pouring, as will beexplained further.

Moreover, in view of the above, it should be noted, that the formingmember and system is also modular, compactable, and portable—as well asselectively configurable—so as to be used for less heavy-dutyapplications and adapted, for example, to selectively create, design andform up a playhouse, fort, dollhouse, theater prop or other suchstructure using a light-weight, conformable material such as a suitablecellular foam material or the like (which could be readily poured—orblown—into the selectively formed up passageways).

In a possible embodiment, panel 12, as shown in FIG. 1, may include twointerconnectable ends 18, 20. Each interconnectable end 18, 20 maydefine an interconnectable flange or other interconnectable element 22,24. Each of the interconnectable elements 22, 24, in one exampleembodiment, may, for instance, define, form, and/or comprise aninterengageable slot 26, 28, respectively.

In the same way, panel 14 may also include two interconnectable ends 30,32. Each interconnectable end 30, 32 may also define an interconnectableflange or other element 34, 36, and each of the interconnectableelements 34, 36, in one example embodiment, may, for instance, define,form, and/or comprise an interengageable slot 38, 40, respectively.Thus, for example, each interconnectable element 22, 34 (at end 180 offorming member 10) and/or interconnectable element 24, 36 (at end 182 offorming member 10) may be adapted to be interconnectable with at leastone other structure.

The modular forming member 10, shown in a “non-interconnected” mode inFIG. 1, comprises various features for use in an “interconnected” modewith, for example, various other forming members, as will be explainedfurther hereinafter.

In one possible embodiment, each of the at least two panels 12,14 mayfurther comprise at least one interconnectable end defining aninterconnectable or other securable element forming an interengageableslot. The interconnectable or other securable element may preferably beadapted to be interconnectable with at least one other structure. Forexample, in one embodiment, each end (e.g., 180, 182) of forming member10 could be connected to another forming member defining a passagewayhaving a substantially linear configuration similar to forming member 10as shown in FIG. 1. However, in other embodiments of the presentinvention, a forming member could have other linear or non-linearconfigurations (e.g., angled, curved, arched, irregular, etc.) or othershaped configurations which will be explained hereinafter.

It will also be appreciated that in one example embodiment, the at leasttwo panels are adapted to be disconnectable after use. With such aconfiguration, the at least two panels (e.g., panels 12, 14) may beadapted to be disconnectable after use to subsequently receive a secondsupply of conformable material, for example, which hardens in place.

Each of the panels, interconnectable ends and interconnectable elementsis preferably formed from metal or plastic but may be made of any othersuitable material having desired properties and characteristics such asfor example, sufficient strength and rigidity to withstand shoring orother forces imparted by any of a variety of materials being retainedand formed by the forming member (e.g., to prevent possible bulging ofthe panels).

Referring still to FIG. 1, one possible embodiment further comprises atleast one spacer connector. However, in a preferred embodiment, twospacer connectors 42, 44 are preferably used to connect the panels 12,14 in spaced relation. Each spacer connector 42, 44, in an exampleembodiment, may preferably comprise a spacer element 46, 48 and aconnector 50, 52 respectively. The connector is preferably a reusableconnector adapted to enable the panels 12, 14 to be disconnected afteruse and reconnected for subsequent use. The example connector 50 in FIG.1 comprises wing nut 65 and a bolt 67 which is selectively sized with athreaded distal end. With such a configuration, each spacer connector42, 44 is adapted to releaseably connect the two panels 12, 14,respectively, in a selectively spaced relationship.

Referring now to FIGS. 1, 2, and 3, it can be seen, that in one possibleembodiment, two apertures 54, 58 and 56, 60 are formed in the panels 12,14, respectively. As can be seen, FIG. 1 shows forming member 10 in an“assembled” mode. FIG. 2 shows forming member 10 without a spacerconnector in a“disassembled” mode. The pair of apertures 54, 56 and pairof apertures 58, 60 in panels 12, 14 are complementary and located so asto line up with one another when installing the “variable-length” spacerconnectors 42, 44 so as to releaseably connect the panels 12, 14 inspaced relation.

As can be seen, each multi-function spacer element 46, 48 serves, in oneaspect, to separate and space apart sides 12, 14 such that passageway 16therebetween has a desired width (i.e. the distance between sides12,14). This desired width may vary depending on the application and maybe established by the selected length of a spacer element. For example,spacer element 46, shown in FIG. 3 has a length equivalent to thedesired width of the passageway, denoted as P_(w). That is, this may bethe desired width of the forming member passageways, denoted as P_(w),for example as shown in FIG. 2.

It should also be recognized that the connector may be any one ofvarious types of reusable, temporary, and/or permanent connectors orfasteners. For example, forming member 10, in some embodiments, could bepermanently connected in an “assembled” mode.

As illustrated in FIG. 3, a threaded nut 64 and bolt 66, in one possibleembodiment, as well those described earlier may also be used toreleaseably secure panels 12, 14. However, at least one end of theconnector is preferably a wing nut or other type of fastener end thatcan be readily tightened or untightened by hand. In other exampleembodiments, the connector may be adapted for latching or for slottedengagement or other types of threaded engagement, or may include othersuitable connectors or fasteners known to a person of ordinary skill inthe art. (For example, the connector could comprise an elongated pinhaving a slotted end adapted to receive a wedge-like member so as tosecure the panels in spaced relation, but permit disconnection merely bybacking the wedge-like member out of the slot in the end of theconnector).

A spacer connector may be installed, in one possible embodiment, byfirst positioning a spacer element between the unconnected panels 12, 14shown in FIG. 2 and then lined up between complementary apertures 54, 56(which preferably have a smaller diameter than the spacer element toprevent the spacer connector from passing through the apertures). Aconnector is then passed (in either direction) through the complementaryapertures, and a fastener element is, in one embodiment, screwed ontothe threaded end of the connector and tightened to secure the panels ina desired spaced relationship.

As noted, the spacing between the panels generally depends on thedesired thickness of the resulting formed wall. If a builder desires,for example, to pour a concrete wall having the actual width of a 2×4(e.g., about 3½ inches), the builder may use a spacer element havingsubstantially the same width as a 2×4. Of course, a spacer element couldbe selectively sized to space the panels apart at any desired width(e.g., 2×6, 2×8, 4 inches, 8 inches, etc.).

In one possible embodiment, prior to assembly of the forming member 10(already shown assembled in FIG. 1), the spacer element 46 (of adisassembled spacer connector 42) would be positioned between theapertures 54, 56 shown in FIG. 2. Then, bolt 67 having a threaded endand a suitable length would be inserted, for example, through aperture56 of panel 14, through the hollow spacer element 46 (being held betweenthe apertures 56, 54 in the panels), and then finally through thecomplementary aperture 54 of panel 12. The threaded end of bolt 67 wouldthen be secured with wing nut 65. The same procedure may be repeated toinstall the second spacer connector 44 (if needed, as will be explainedfurther). In this way, the spacer connectors (e.g., 42, 44) are adaptedto releaseably connect panels 12, 14 in a predetermined selected spacedrelationship depending on the desired thickness of the formed wall.

It should be noted that if only one spacer connector is desired for usewith a forming member, any other unused apertures in the panels can beplugged or sealed. Moreover, the panels can also be configured with onlyone aperture each and positioned as desired. In other embodiments, aforming member may be configured with no apertures and not held inspaced relation by a spacer connector—but instead by securing theinterconnectable ends to another structure (or to adjacent formingmembers as will be explained further hereinafter).

Turning again to FIG. 1, in one possible embodiment of the presentinvention, the interconnectable ends (for example, 18, 30) of formingmember 10 may be adapted to be interconnected to at least one otherstructure as noted. More particularly now in FIGS. 1-5, and as bestshown in FIG. 5, in a possible embodiment of the present invention, theat least one other structure may comprise, for example, at least oneother forming member 78. Forming member 10 is shown partlyinterconnected, while forming member 78 is shown in an “interconnected”mode with forming members 10 and 218 at the other end.

Forming member 78 is preferably interconnectable with forming member 10at one end, by engagement member 68, forming an interconnection slot 70,and is interconnectable to forming member 218, at the other end, bysimilarly configured engagement member 81 (see FIGS. 4 and 5). As shownin FIGS. 1 and 5, the engagement member 68 is receivable by both aninterengageable slot 28 of an interconnectable element 24 (see FIG. 1),and an interengageable slot (not shown) of interconnectable element 79of forming member 78 as shown in FIG. 5. It will be appreciated that thefeatures of the interconnection system, in this embodiment, enableadjacent forming members (e.g., 10 and 78; 78 and 218; etc.) to beeasily and quickly interconnected without the need for multi-componentfastening systems or time-consuming threaded fasteners. Also, it shouldbe recognized that although FIG. 5 shows multiple forming membersinterconnected as well as stacked, one possible embodiment does notrequire stacking forming members to form up a desired wall as will beexplained further herein.

To further illustrate an interconnectable feature of the forming systemand member using an engagement member, another possible embodiment ofthe present invention is shown in FIG. 11. FIG. 11 provides a somewhatdifferent perspective of another forming member 82 having panels 97A,97B and complementary engagement members 84, 85 (and having otherfeatures that will be further explained in subsequent paragraphs). Inthe view shown, the engagement member 84 forms an interconnection slot90. The engagement member 84 is selectively sized and shaped withinterconnection slot 90 such that the engagement member 84 is adapted tobe received by both the interengageable slot 92 of interconnectable end93 and an adjacent interengageable slot from another forming member (notshown) which could be connected at a later time. (Preferably, in oneembodiment, the slot 90 of the engagement member 84 extends downwardlysuch that the engagement member 84 is adapted to be received by upwardlyextending interengageable slots (e.g., 92, etc.) of the forming member82 and some other forming member which could be interconnected thereto).

Referring again to FIGS. 1, 4, and 5, in one possible embodiment, itshould be recognized that the engagement member is selectivelyconfigured with various features for functional cooperation with theinterconnectable ends of forming members adapted to be interconnected.That is, in an exemplary embodiment, engagement member 68 (as shown inFIG. 4) has various features adapted to foster securely interconnectingthe slotted interconnectable elements of forming members positionedadjacent one another.

For example, an engagement member, in one embodiment shown in FIG. 4,preferably has a width denoted by E_(w), a length denoted by E_(l), aslot width denoted by E_(s), and an unslotted depth denoted by E_(d).The forming member in FIG. 1, in one embodiment, has an interconnectableelement (e.g., 34) with a slot depth as denoted by S_(d) (shown in FIG.1).

It will be appreciated that in one embodiment, the un-slotted depthE_(d), of the engagement member 68 is at least substantially equivalentto the slot depth as denoted by S_(d) of slot 38 of interconnectableelement 34 (as shown in FIG. 1). In this way, the engagement member isconfigured to functionally cooperate with the configuration ofinterconnectable element 34, such that the unslotted portion 71 ofengagement member 68 will be received (slidably in one embodiment) bythe interengageable slot 38 of interconnectable element 34.

Likewise, the engagement member (shown in FIGS. 1 and 5) would also beconfigured to functionally cooperate with another similarly configuredforming member having a complementary interconnectable element with aninterengageable slot positioned immediately adjacent slot 38.

It should also be noted that, in one embodiment, the engagement member(with the slot width denoted by E_(s)) is adapted to be received by bothof the interconnectable ends of immediately adjacent forming members(e.g., see FIG. 5, slotted elements 24, 79 of forming members 10, 78respectively). With such a configuration, a user could quickly andeasily slide the engagement member so as to be received simultaneouslyby both adjacent interengageable slots—so as to connect theinterconnectable ends of each of the forming members. The remaininginterconnectable ends could be connected in the same manner. (Note thatthe geometry and structures shown in the figures are not to scale, donot necessarily depict the actual size of the structures, and may bevaried as needed to effect any desired interconnectability between theforming members).

The interconnection slots of engagement members and the interengageableslots and interconnectable elements and ends of the forming members, invarious embodiments, may be suitably sized and shaped to provide a snugor loose interconnection. Also, the engagement member andinterengageable slots may be configured for frictional engagement toreduce the possibility of the engagement member disengaging or anyundesirable disconnection between the ends of adjacent forming members.In one embodiment, for example, when using the forming system to formout a concrete wall, preferably in most instances, a substantially snugfit will be desired between adjacent forming members so as to avoidunwanted leakage through the seams between adjacent forming members.However, when using the forming system for less viscous materials, alooser fit may be suitable. In addition, in some situations (whileretaining and forming certain materials), controlled seepage through theupper and lower portions of the seams between adjacent forming membersmay be desirable to promote and foster, for example, more uniformcuring. Also, a sealer could be used along lateral and longitudinalseams between forming members to minimize leakage (and also to minimizeresulting seams in the hardened wall; however, seams may also be shavedoff as desired).

In view of the foregoing, an interconnectable (or securable) element ofa “first” forming member may be disposed immediately adjacent aninterconnectable (or securable) element of a “second” forming member. Anengagement member forming an interconnection slot may be furtherincluded with the engagement member receivable by both aninterengageable slot of a securable member of the “first” forming memberand an interengageable slot of a securable element of the “second”forming member. In this way, the “first” and “second” forming membersmay be interconnected. Moreover, a plurality of forming members may besimply and easily interconnected next to one another so as to form aplurality of longitudinally extending passageways in communication withone another.

Turning again collectively to FIGS. 1-5, and in particular FIG. 1, inanother possible preferred embodiment of the present invention, each ofthe panels 12, 14 may further preferably comprise a base flange 94, 98,respectively, and a support member 96, 100, respectively. With thisconfiguration, the support members of a given forming member are adaptedto cooperate to alignably receive the base flanges of another formingmember being stacked on the given forming member.

The support members 96, 100 (see FIGS. 1 and 5) of forming member 10, inone embodiment, are adapted to cooperate to alignably receive the baseflanges 104, 106 of forming member 156 (shown in FIG. 5) being stackedon forming member 10.

In this way, each of the support members of a given forming member maybe preferably configured and oriented in opposing relation so as toalignably receive each complementary base flange of another formingmember. Such a self-alignment feature fosters easy and simple stackingof forming members and aids in building a more plumb form wall.

In view of the foregoing, it can be seen in FIG. 5, that a plurality ofstacked forming members would define a wall of forming members (e.g.,10, 156, 158, 160) defining a plurality of vertically-extendingpassageways to retain a conformable material.

It should be noted, however, that with the flexible and configurabledesign features of the panels 12, 14, the panels shown in FIG. 1, maynot comprise (or need) any support members (e.g., 96, 100). That is, insome embodiments, the interconnectable forming member may be configuredto be used to form a passageway (e.g., horizontally-extending and/orvertically-extending, etc.) to pour concrete to make a “footing,”“retaining wall,” or other structure. Moreover, the panels of eachforming member could be cooperatively and sufficiently sized (assuitably large panels; e.g., 4 ft×4 ft; 4 ft×8 ft; etc.) andinterconnected to form up a large wall (heightwise and/orlengthwise)—without the need for stacking other forming members.

Turning again to FIG. 1, it will also be appreciated that, in onepossible embodiment, each support member 96, 100 is disposed at least inpart proximate a top edge 116, 118 of a respective panel 12, 14 witheach support member preferably being oriented substantially orthogonalwith respect to its panel. In this way, the panel is, in one embodimentfor example, further reinforced to inhibit unwanted flexing while theforming member is retaining concrete or some other material for extendedperiods of time (e.g., during the curing process). This reinforcingfeature also aids in maintaining the overall conformation of a formed upwall of interconnected and stacked forming members (e.g., FIG. 5) aswell as the conformation of the plurality of passageways.

A support member is preferably integrally formed with its respectivepanel so as to foster ease of manufacture and to strengthen the panel.However, a given support member can be further strengthened and/ordisposed, or for example, connected to the top edge of its respectivepanel in any of various ways such as by welding, bracketing, bracing,riveting, adhering, or by other reinforcing or connection systems. Inaddition, if further reinforcement is desired, one or more vertically orotherwise oriented rib structure(s) could be connected between eachsupport member and base flange of a panel and/or one or morehorizontally or otherwise oriented spar structure(s) could be connectedbetween each interconnectable end of a panel.

In one possible embodiment, each of the support members 96, 100 of thepanels 12, 14 further comprises a support flange 108, 112 and a guideflange or guide member 110, 114, respectively. The guide flanges ormembers 110, 114 are preferably disposed in opposing spaced relation andare preferably oriented, at least in one embodiment, substantiallyorthogonal to the support flanges. In this way, opposing guide flangesof a given forming member are in functional cooperation with each otherto reinforceably secure the base flanges of another forming memberstacked thereon. In effect, the guide flanges may serve as alignmentflanges. (For example, see FIGS. 1 and 5, forming member 156 stacked onforming member 10; forming member 158 stacked on forming member 156;forming member 160 stacked on forming member 158; etc.). It should alsobe noted that the guide members could also be flared out at the topedges (or at the bottoms) and inclined with respect to one another withthe top edges further apart than the bottom edges to foster stacking.

In another possible embodiment of the present invention, each of the atleast two panels (e.g., 12, 14) further comprises a base flange which isextending from each panel away from a passageway of the forming member,and a support member on an opposite side from the base flange with thesupport member extending away from the passageway. In such anembodiment, the support member further comprises a guide member adaptedto alignably receive a base flange of another forming member whenstacked on the forming member. In this way, the at least two panels arealignable with at least two panels of another forming panel.

In addition, it will be appreciated that the engagement member also hasdesign features interoperable with the design features of themulti-purpose interconnectable ends and support members. In one exampleembodiment, as shown in FIG. 1, the top edge 35 of interconnectable end30, is lower than the top edge 118 of panel 14. Thus, there is a spaceor gap as denoted by E_(g) (see FIG. 1). As shown in FIGS. 4 and 5together, flange 69 of engagement member 68 is disposed above the topedges of interconnectable ends 20, 77. In one embodiment, flange 69 isadapted to rest on the top edges of and be supported by interconnectableends 20, 77 (of forming members 10, 78).

As illustrated in FIG. 5, the base flanges of forming member 212(configured in a similar manner as forming member 10 in FIG. 1) areadapted to be alignably received by the support members of formingmember 78. In addition, a portion of the base flange of member 212 mayalso, in a possible embodiment, be adapted to be supported by flange 69of engagement member 68. With this interoperable configuration, it cannow be seen that the interconnectable ends are configured to aid insupporting and reinforcing the flange 69 when forming member 212 isstacked on forming member 78.

As best shown in both FIGS. 4 and 5, another cooperatively functionaldesign feature can be seen. In one possible embodiment, the engagementmember 81 (as well as the various other engagement members) has a widthdenoted by E_(wl), (see FIG. 5) adapted to fill in the space denoted byS_(g) between support members (e.g., of forming members 78, 218). Inthis way, the engagement member is also adapted to better support thebase flanges of the form members stacked on it (e.g., 212, 220).

In another example embodiment, at least one aperture is formed in eachbase flange and at least one complementary aperture is formed in eachsupport member. In a possible embodiment, as shown in FIG. 14,complementary apertures 150, 152 are formed in a base flange 140 and asupport flange 144, respectively and are alignable such that a retainingmember, fastener or connector or the like is insertable through theaperture 150 of the base flange 140 and the complementary aperture 152of the support flange 144 to secure the base flange to the supportflange. In one embodiment, a retaining member such as pin 154 may beinserted through apertures 150, 152, as shown in FIG. 14 to securealignment of the base flange 140 with respect to the support flange 144.Such a configuration not only serves to selectively vertically align thestacked forming member—and secure the conformation of the respectivepassageways—but also aids in reinforcing the connection between the twoforming members. Thus, in other embodiments, a guide flange 146 may notbe needed.

In addition, the “multi-purpose” base flange, in one possibleembodiment, also provides a stabilizing function. That is, with the baseflange flared out or extending preferably substantially perpendicularwith respect to the plane of its respective panel—and away from thepassageway—the base flange serves as a platform-like structure tostabilize the forming member. Of course, the base flange may also beselectively widened (as well as the complementary support member(s)) toprovide further stability. In addition, a forming member can be furtherstabilized by using the apertures of the base flange with a connector(e.g., nail, spike, connector, fastener, etc.) or the like insertedthrough the aperture to anchor the base flange to a surface—or anotherforming member.

It should also be recognized that various features of the versatileforming system may be selectively configured and dimensioned such thatvarious components operate together to prevent shoring and misalignmentwhen a plurality of interconnected and stacked forming members are beingused. For example, the spacer can be enlarged, thickened, reinforced,and/or strengthened to maintain the inner configuration, alignment, and“conformation” of vertically- and horizontally-extending passagewayscreated by a formed up wall of interconnected and stacked formingmembers.

In this way, the forming members are adapted to retain and keep concreteor cement for example, in a uniform thickness and height within thepassageways—and thus produce a straight wall, vertically andhorizontally. It should be appreciated, that with the configuration ofthe forming members, the forming members may be stacked directly on oneanother, or staggered such that any seam that might appear on the wallwould also have a staggered, block wall-type appearance.

In addition, the spacer elements could also include one or more recessesand/or one or more protuberances, outwardly extending lugs, or otherfeatures to aid in more firmly tying rebar or the like in a vertical orhorizontal manner to aid or to facilitate securing the formed up wall toa foundation, footing, roofing member or some anchoring structure. Thespacer elements also may define a groove, aperture, or eyelet sized tocomplementarily receive rebar securely (with or without tying) in such away as to provide further reinforcing strength to the formed wall. Forexample rebar may have a diameter of about one quarter inch or otherdimension as required for desired reinforcement characteristicsdepending on the resulting thickness of, in one embodiment, a concretewall and the engineering design specifications. The spacer elementgroove could be sized accordingly.

The outer surface of the elements or other passageway structures asnoted herein may also be textured, coated or treated so as to promoteand/or inhibit bonding or the like between such structures and aconformable or settable material (e.g., concrete, etc.). Also, thepanels interconnectable ends and/or elements, support members and/orspacer connectors may be formed from a durable, heavier gauge metaldepending on the use. For example, the panels may be made fromgalvanized steel sheets, aluminum, copper, tin, or various other metalsdepending on the application.

In view of the foregoing, the forming system effectively providesvarious interoperable and functionally cooperative reinforcing features,as well as others as noted herein, which foster more snuggly securingtogether an entire wall or enclosure of interconnected and stackedforming members (e.g., see FIG. 5, items 10, 78, 218, 156, 212, 220,158, 214, 222, 160, 216, 224, etc.)—prior to pouring a desiredmaterial—and as such, the conformation of the plurality of passagewaysmay be better maintained.

Referring now to FIGS. 6A and 6B, in another possible embodiment, aforming member 310 is shown. It should be appreciated that the size,dimensions and interrelationships of the various features of the formingmember 310 may be different than that of forming member 10. That is, theoverall dimensions, size, shape, and other physical features of anygiven forming member are selectively and flexibly configurable dependingon the application the forming is being used for. For example, thespacing between panels 312, 314 may be configurable so as to form anarrower and/or taller passageway 316, or alternately a wider and/orshorter passageway. Also, the lengths of the support members 396, 400may be shorter relative the lengths of panels 312, 314. Other componentssuch as interconnectable ends 318, 320, 330, 332, interconnectableand/or or securable elements 322, 324, 334, 336 may have any of avarious suitable dimensions, sizes, or shapes (or e.g., rounded shapesor corners, angled ends, etc.), and interengageable slots 326, 328, 338,340 could be deeper or shallower or be oriented at an angle with respectto the vertical edges of the interconnectable ends with an engageablemember having a complementary dimensioned slot or an angled slot.Moreover, the interconnectable ends could be hinged or bendable in sucha way that adjacent forming members could be angled with respect to oneanother to create a variety of passageway arrangements and formed wallconfigurations.

Also, as shown in FIG. 6A, additional apertures (418, 420, 422, 424) maybe provided in guide flanges (e.g., 414, 416) (to facilitate securingcomplementary base flanges of another forming member with a fastener orto secure the flanges to some other structure); moreover, apertures(e.g., 426, 428, 429, 430, 432, 434, 436, 438 (not shown)) of theinterconnectable ends, apertures (e.g., 435, 437, 439, 441) of the baseflanges (e.g., 394, 398) or apertures (e.g., 421, 423 (not shown), 425,427) of the support flanges may also be selectively sized and positionedas needed for a particular forming layout. These features and aperturescould be used with any forming member configuration (e.g., 10, 310, 78,156, 224, 172, 230, etc.) and may be used for various purposes such asfor example, securing the forming members to braces, other anchoringstructures, other forming members, etc.

When forming up a “footing” for a wall for example, in one embodiment,any of the various apertures (e.g., 426, 428, 429, 430, 432, 434, 436,438) of the interconnectable ends, may be used with a fastener to secureone end of a forming member to another. That is, for a formed upfooting, or for the bottom row of forming members of a formed up wall(e.g., see 10, 78, 218 in FIG. 5), engagement members (e.g., 68, 81,etc.) may be used to secure the upper portions of the adjacent forms(e.g., 10, 78, 218). However, the lower portions (and/or the upperportions) of the forms could be secured together by inserting fasteners,connectors or the like through apertures (shown in FIG. 6A (but notshown in FIG. 1, but which could be provided)) in the interconnectableends to more snuggly secure the lower portions of the adjacent formingmembers next to one another so as, for example, to further preventshoring or buckling or the like once a heavy material (e.g., concrete,etc.) is poured into the formed up wall or footing.

Likewise, apertures (e.g., 435, 437, 439, 441) of the base flanges(e.g., 394, 398) may be used to anchor the forming members to theground, foundation, sidewalk, flooring or some platform-like structure(or even a wall in some instances).

Moreover, it will be appreciated, that a footing for a retaining wall orthe like could also be formed up and poured first before a retainingwall is formed up. The footing could be formed up by using a pluralityof forming members that are wider than the width (in one embodiment asdenoted by P_(w) in FIG. 2) of the forming members that will be used toform up the retaining wall. It should be recognized that the spacingbetween the support members of the forming members of the footing couldbe adapted, modified or reduced so that narrower forming members for theretaining wall could be stacked on the formed up footing before pouringany concrete. Also, the footer could be first formed up and poured; andafter the concrete hardens, the retaining wall forming members could bepositioned atop the footing and tied in as appropriate with rebar or thelike.

With any type of forming system, it should be noted that a builder mustensure that needed bracing and supports are used as well as a properbase for the formed up wall before and after pouring a material such as,for example, concrete. Another consideration, however, is to not stackthe forming members too high so as to create excessive pressure on lowerrows of forming members to be filled with concrete. Instead, just thelower rows or levels could be filled with concrete first. After theconcrete cures, then, successively higher rows can be filled and curedin stages as needed.

Referring now to FIG. 6B, in one possible embodiment, spacer connectors452, 454 may be selectively dimensioned or located, for example,horizontally, vertically, or as desired within the passageway 455 asneeded for a particular application. Each of the panels 440, 442 andtheir interconnectable ends 444, 446, 448, 450, respectively may beunitarily formed from one section of material or constructed inseparable or connectable components having a material thickness suitablefor heavy-duty or other applications. For example, the panels 440, 442and the interconnectable ends could be formed from a higher gauge,thicker metal or other material. In addition, as shown, the base flangescould have the same length as the support members 456, 458.

The various components of the panel could also be connected together invarious ways. For example, each of the interconnectable ends and/orelements could be connected to a respective panel by any of a variety ofmethods, such as welding, hinging, fastening (riveting, threadedfasteners, removable or permanent connectors, etc.)

It will also be appreciated that the forming member has a modular,portable configuration. The forming member could be constructed fromonly two unitary structures or integrated panels and at least one typeof one spacer connector. Such a configuration would foster ease ofassembly or disassembly as well as handling, transporting, and storageof the forming member(s).

Referring now to FIG. 6C, in one example embodiment, a unitary structure460 is reusably combinable with other unitary structures to create formsor forming members to receive a settable material. The unitary structure460 preferably comprises a panel 462, at least one integrally formedinterconnectable end, but preferably two interconnectable ends 464, 465with each interconnectable end defining a securable or interconnectableelement 466, 467, respectively. The unitary structure 460 preferablyfurther comprises a base flange 468 integrally formed at a firstperipheral edge 470 of the panel 462, and a support member 472integrally formed at a second peripheral edge 474.

The at least one integrally formed interconnectable end, in oneembodiment, or preferably each of two integrally formed interconnectableends, could also define an interconnectable element forming aninterengageable slot with its respective interconnectable end integrallyformed at a peripheral end of the panel.

The panel, the at least one integrally formed interconnectable end, baseflange, and support member are preferably of a one-piece constructionand comprise at least one of sheet metal or plastic. The spacerconnector components may also be made from metals, plastics or othermaterials as noted herein. Also, the panels, interconnectable endsand/or elements, support members and/or spacer connectors may be formedfrom a durable, heavier gauge metal depending on the use. For example,the panels may be made from steel or galvanized steel sheets or aluminumas well as other metals (copper, tin, etc.). However, various othersuitable materials, known to one of ordinary skill in the art, forforming applications could be used as well. Each panel may have acertain gauge wall thickness suitable for retaining and forming heavieror less viscous materials. On the other hand, each panel may have alesser gauge wall thickness for retaining and forming lighter or moreviscous materials. For example, forming members used for concrete mayhave a wall thickness, in one possible embodiment, in the range of 1/16of an inch to ⅛ of an inch. In another possible embodiment, the wallthickness may be in the range of ⅛ of an inch to ¼ of an inch; in otherembodiments the wall thickness of the various forming member componentsand structures may vary depending on the application. One possiblematerial may be a steel sheet metal or aluminum; others will beexplained further hereinafter.

In manufacture, the unitary structure could be formed with a press orother suitable machinery to form substantially orthogonal bends alongperipheral edges of the panel 462 (e.g. 470, 474, 476, 478, 480) to forma unitary member as shown in for example, in FIG. 1 or 6A (e.g., 183,185, 313, 317). Also, some or all edges and/or corners (e.g., 461, 463,464, 465, 471, 473, etc.) and other structures may preferably be roundedor smoothed using a grinder or the like for ease of handling, to improvestorage, etc.

It should also be recognized, that the same unitary structure 460 may bemanufactured and used interchangeably for either side of the formingmember; thus, a forming member could be manufactured from only twounique components: the unitary member and the spacer connector(comprising the spacer element and connector) and the entire formingmember could be constructed from only two unitary members and one or twospacer connectors.

In addition, such a unitary structure and/or separable portions thereof(e.g., as described with respect to forming member 10, 172, etc.)—aswell as the entire forming member—could be made from wood, fiberglass,or molded from plastic using injection molding or other suitablemanufacturing processes. In some embodiments for certain applications,various structures of the forming member may be formed from high-densitypolyethylene, polypropylene or other suitable polymers or materialswhich satisfy desired strength requirements. At least some of theforming member may also be manufactured from various composite materialsto make the forming member suitably lightweight and durable for varioususes in the construction industry or for various applications in othertechnology areas or industries.

It will be appreciated, that with such a unitary, modular, andcompactable configuration as noted herein, a plurality of formingmembers—in a “disassembled” mode—can be more efficiently and easilytransported to a construction site. Once at the site, the formingmembers can then be assembled using whatever sized spacer connectorlengths are needed for a desired wall thickness and the forming systemcan be easily installed on site. On the other hand, in view of theportability of the forming members, they can also be pre-assembled at afactory, and, if needed, be easily stacked in certain pre-determinedformed up wall dimensions for shipment.

It should also be emphasized, that the weight and portability of theforming system provide many advantages compared to various othersystems. With a lighter-weight configuration in use, the forming memberscould be easily lifted and stacked and/or interconnected. In addition,the forming member panels and spacer connectors are easy to store andwould generally take up little space, comparatively, because the panelscould be nested and stacked in a disassembled mode. Thus, many thousandsof such “nestable” panels and spacer connectors could be manufacturedand stored in inventory without requiring substantial space. Moreover,even in an “assembled” mode, a wall of portably and compactly configuredforming members, could be stacked and conveniently kept in a storagefacility.

In view of the foregoing, the simplicity and efficiency of the formingsystem can be appreciated. Exemplary embodiments of the presentinvention include various configurable features of a forming systemfostering effective and versatile construction and a quick and easymethod for manufacture and assembly of a plurality of forming members.In addition, the cost per individual form would be selectively variableand controllable depending on, for example, the manufacturing costs andthe material used.

In effect, the modularity, flexibility, simplicity, and versatility ofthe forming members provides a selectively arrangeable forming systemhaving features that foster a variety of designs, shapes andarrangements depending on what type of building, shed, containment wall,footing, garage, room, house (exterior walls, or interior walls) orother structure is being formed up and what type of material is beingused. In addition, the forming member can be secured to existingbuilding structures and for example, used to tie into and/or replaceexisting wood or other walls.

Turning now to FIGS. 7 and 8, several more of many possible embodimentsare shown. The embodiment in FIG. 7 illustrates at least part of asubstantially non-linear forming member 172 comprising at least twopanels in spaced relation (not yet showing the spacer connector(s)) andconfigured so as to define a passageway having a substantiallyninety-degree or right angle configuration adapted to retain aconformable material. Various embodiments may be formed as a corner-typeforming member including forty-five-degree, thirty-degree angle corners,and other angled configurations or the like. Preferably, forming member172 comprises a first panel 174 having a substantially ninety-degreeconfiguration and a second panel 176 also having a complementarysubstantially ninety-degree configuration, with the first panel 174being shorter, in one possible embodiment, than the second panel 176.Each of the panels 174, 176 may be formed from one panel which is bentinto a ninety-degree configuration. Or, each panel could be comprised oftwo smaller panels connected together in any of a number of ways thatwould be known to a person of ordinary skill in the art.

Forming member 172 preferably further comprises spacer connectors (notshown in FIG. 7), with each spacer connector comprising a spacer elementand a connector. In one embodiment, the spacer connectors may be similarto those used in forming member 10 (and/or 310, etc.). The spacerconnectors are adapted to releaseably secure first panel 174 to secondpanel 176 in a manner somewhat similar to spacer connectors 42, 44included with forming member 10 (in a possible embodiment as discussedabove). To install the spacer connectors, the spacers may be positionedwithin the interior of the passageway 178 and located between theapertures (e.g., 184A of panel 174 and 184B (not shown) of panel 176 or186A of panel 174 and 186B (not shown) of panel 176). A connector may beinserted, for example, first through aperture 184A formed in panel 174,then through the spacer element (preferably having a hollow tube-likebody), through the complementary aperture 184B formed in panel 176 andthen secured with a connector fastener so as to preferably releaseablyconnect panel 174 to panel 176. Another spacer connector could then beconnected in a similar manner through apertures 186A, 186B. It should beappreciated that the connectors can be initially inserted either way,for example through 184A or 184B and thus be tightened or untightenedfrom whichever side of the forming member is most desirable. With thisbi-directional installation feature, all fastening members of aplurality of forming members (e.g., 10, 310, 172, etc.) can beconfigured such that they are manipulable from one or any side of aformed up wall. Or, moreover, if there is an obstacle blocking access toone side of a given forming member, the forming member connectors may beinstalled such that they are disconnectable and removable from theaccessible side. It should be recognized, that if a side of one or moreforming members is blocked by an existing permanent wall or otherstructure (e.g., when forming up a footing in a trench or the like),each connector, comprising for example, a bolt and nut in one possibleembodiment, would need to be installed such that the bolt (having adesired length) can be pulled out on the side opposite (or in someinstances on the same side as) the existing permanent wall or structure(e.g., side of the trench). In other words, there needs to be sufficientroom on the side to remove the entire shaft of the bolt. Otherwise, theforms may not be removable. Thus, a row of forming members, in someembodiments, may be interconnected in a longitudinally-extending rowparallel and positioned immediately adjacent an existinglongitudinally-extending existing wall—if there is sufficient spacebetween the side of the row of forming members and the existing wall.Also, the spacing in various embodiments should be sufficient so as topermit the bolt head and/or nut to be manipulated and removed so thepanels can in turn be disconnected and removed. In other embodiments,the forming member may also have a nut that is fixed or welded in placeon the panel such that it does not need to be manipulated by hand orwith a tool to prevent it from turning when the bolt is being tightenedor untightened.

The panels 174, 176 in one embodiment, also preferably comprise baseflanges 204A, 204B, 206A, 206B and support members 208A, 208B, 210A,210B, respectively with the support members being adapted to alignablyreceive the base flanges of another complementarily configuredninety-degree forming member (or corner) (or other stackable formingmember 10, 310, etc.) being stacked on the forming member 172. Formingmember 172 further preferably comprises interconnectable ends andelements similar to, in one embodiment, forming member 10, which areconnectable with an engagement member. Also, forming member 172 couldform any apertures as described above with respect to forming member 10(and/or 310, etc.) as needed.

It should also be recognized that a forming member could define apassageway having any of a variety of substantially non-linear (orlinear) configurations such as noted above, or for example, having acurved, arched, rounded, zigzagged, V-shaped, U-shaped, or othernon-linear configuration, or any other shaped configuration suitable toform a passageway for receiving a material which is preferablyconformable. The forming member could also have an X-shaped, T-shaped(as will be explained hereinafter) configuration and the forming systemcould include any of various combinations or arrangements ofsubstantially linear and/or non-linear forming members or formingmembers having other configurations.

In addition, in view of the flexible configuration of the formingmember, two or more panels (as well as the interconnectable ends) couldbe parallel or be selectively disposed at angles (laterally orlongitudinally, or vertically or horizontally), or, for example,inclined with respect to each other, such that a passageway would have awedge-shaped, trapezoidal cross-section, or other orientedconfigurations (e.g., as viewed from the top or an end of a formingmember) (or at converging or diverging angles maintained with variousspacer connector lengths), as desired along the span of a formed upwall. Of course, the panels of adjacent forming members would beoriented and configured such that the interconnectable ends, supportmembers and/or base flanges had a complementary fit with other adjacentforming members as needed. In this way, forming members could beconfigured with various opposing panels at selected angles, or withinterconnectable curved panels (e.g., intermittently located in a formedup wall as desired, perhaps with an inner panel being planar and anouter panel being curved—such that a poured concrete wall would have aselectively curved outer surface) or other geometrical patterns to as todefine a passageway having any of a number of selected configurations orarrangements for various applications, design uses or aesthetic appeal.

Referring now to FIG. 8, another example embodiment is illustratedincluding at least three panels configured so as to define a passagewayhaving a substantially T-shaped configuration adapted for retaining aconformable material.

In one embodiment, the preferably T-shaped forming member 230 comprisesat least three panels disposed in a spaced relationship (not yet showingthe spacer connectors) and configured so as to define a passagewayhaving a substantially T-shaped configuration. Forming member 230preferably, comprises a first panel 232 having a substantiallyninety-degree or right angle configuration, a second panel 234 having asubstantially linear configuration and a third panel 236 also having asubstantially ninety-degree or right angle configuration. The threepanels 232, 234, 236 are preferably dimensioned, shaped and disposed ina complementary arrangement, in one embodiment, as shown in FIG. 8, soas to form a T-shaped passageway. The first panel 232 and third panel236 preferably have the same dimensions. As with forming member 172,each of the panels 232, 236 may be formed from one panel which is bentinto a ninety-degree configuration or each panel could be comprised oftwo smaller panels connected together using any of a variety of waysknown to one of ordinary skill in the art.

Forming member 230 preferably further comprises three spacer connectors(not shown in FIG. 8), with each spacer connector comprising a spacerelement and a connector. In one embodiment, the spacer connectors aresimilar to those used in forming member 10. The spacer connectors areadapted to releaseably secure first panel 232 to second panel 234 in amanner somewhat similar to spacer connectors 42, 44 included withforming member 10 (in a possible embodiment as discussed above). Toinstall the spacer connectors, the spacers may be positioned within theinterior of the passageway 238A, 238B and secured through the aperturesshown in a similar manner as discussed above with respect to formingmembers 10 (and/or 172, etc.). However, preferably three spacerconnectors are used to releaseably secure the panels 232, 234, 236together in a T-shaped configuration.

Also, as shown in FIG. 8, the panels 232, 234, 236, in one embodiment,also preferably comprise base flanges 240A, 240B, 242, 244A, 244B andsupport members 246A, 246B, 248, 250A, 250B, respectively with thesupport members being adapted to alignably receive the base flanges ofanother complementarily configured T-shaped forming member (or, forexample, in part other complementary forming members 10, 172, 310, etc.)being stacked on the forming member 230. Forming member 230 furtherpreferably comprises interconnectable ends and elements similar to, inone embodiment, forming members 10, 310 (and/or 172, etc.), which areconnectable with an engagement member. Also, forming member 230 couldalso form various apertures as described above with respect to formingmembers 10, 310 (and/or 172) as needed.

In addition, it should also be emphasized that in a possible embodiment,each of the linear or non-linear forming members is preferablyconstructed with a spacer element having a pre-designated width. Thus, aformed up wall of forming members used for a retaining wall, forexample, may be configured such that the poured retaining wall mighthave a width as denoted by the passageway width P_(w) (e.g., in FIG. 2).In some embodiments, each forming member of the formed up retaining wallwould have a width P_(w) as shown in FIG. 2 and as established by, forexample, a spacer element 46, as shown in FIG. 3.

In another possible embodiment, a forming member may be configured toclose or seal off a passageway and in effect form an end panel (or wall)or end cap. The forming member may comprise one or more panelsconfigured so as to define a passageway having a partially closedconfiguration. Referring to FIG. 9, in one embodiment, an end formingmember 260 comprises a panel 262. Panel 262 may be three-sided (e.g.,264A, 264B, 264C) and may be formed from one panel or piece of materialwhich is bent or formed into the end-shaped configuration as shown inFIG. 9. With this configuration, a portion of the panel including twosides 264A, 264B would be bent to form a substantially a 90-degreeconfiguration. Then sides 264B, 264C, respectively would be bent to formanother substantially a 90-degree configuration as shown in FIG. 9. Inaddition, in another embodiment, panel 262 could be comprised of, forexample, three smaller panels configured so as to define a passagewayhaving a partially closed configuration and with each of the panelsconnected together in any of a number of ways.

End forming member 260 may further comprise one or more spacerconnectors (not shown in FIG. 9), with each spacer connector comprisinga spacer element and a connector. The spacer connectors may be similarto those used in other forming members (e.g., 10, 310, etc.) andappropriately formed apertures could be provided as needed. However,side 264B serves as a spacing structure to separate and space apartsides 264A, 264C such that passageway 266 therebetween has a desiredwidth (i.e., the distance between sides 264A, 264C). This desired widthmay vary depending on the application and may be established by thelength of a spacer element. For example, spacer element 46, shown inFIG. 3 has a length equivalent to the width of the passageway, denotedas P_(w). This may also be the desired width of the forming memberpassageways (e.g., see width denoted as P_(w) in FIG. 2) (As notedabove, this width may be the same as the width of a 2×4 or other sizedboard, etc.). Thus, side 264B would, in certain embodiments preferablyhave a width substantially equivalent to the length of the spacerelements used to establish the passageway spacing in the formingmembers.

The panel 262 in one embodiment, also preferably comprises base flanges268A, 268B, 268C and support members 270A, 270B, 270C, respectively withthe support members being adapted to alignably receive the base flangesof another complementarily configured forming member (or other formingmember 10, 172, 230, 310, etc.) being stacked on the end forming member260. End forming member 260 further preferably comprises a pair ofinterconnectable ends and elements similar to, in one embodiment,forming member 10 (or 172, 310, etc.) which are connectable with anengagement member. Also, end forming member 260 could also form variousapertures as described above with respect to forming member 10 (and/or310, etc.) as needed.

In one other possible embodiment, an end panel or forming panel may beconfigured to seal off a passageway and in effect form an end wall.Referring to FIG. 10, in one embodiment, an end panel 272 comprises apanel 274. At least a portion of panel 274 could serve as a spacingmember and would, in certain embodiments, preferably have a widthsubstantially equivalent to the length of the spacer elements used toestablish the passageway spacing of the forming members. That is, asnoted above, the desired width may vary depending on the application andmay be established by the selected length of a spacer element. Forexample, as noted, spacer element 46, shown in FIG. 3 has a lengthequivalent to the desired width of the passageway, denoted as P_(w).This may also be the desired width of the forming member passageways(e.g., see width denoted as P_(w) in FIG. 2).

The panel 274, in one embodiment, also preferably comprises a baseflange 276 and support member 278 with the support member being adaptedto alignably receive the base flange of another complementarilyconfigured end panel (or other forming member 10, 172, 230 310, etc.)being stacked on the end panel 272. Also, end panel 272 could also formvarious apertures in the panels, flanges, and/or members as describedabove with respect to forming members 10 or other forming members asneeded.

It should be recognized that end panel or forming member 272, in onepossible embodiment, preferably comprises two interconnectable ends 280,282. Each interconnectable end, in one embodiment, comprises a pair ofspaced interengageable flanges. With this configuration,interconnectable end 280 would preferably comprise a pair of spacedinterengageable flanges 284A, 284B while interconnectable end 282 wouldpreferably comprise a pair of spaced interengageable flanges 286A, 286B,as shown in FIG. 10. It will be appreciated that the interengageableflanges are specially configured such that they may be interconnected tothe interconnectable ends of an adjacent forming member (such as, forexample forming member 10)—without the use of an engagement member. Withsuch a configuration, a selected pair of interconnectable ends of aforming member would not need a specially configured interconnectableelement defining an interengageable slot; also, as noted, an engagementmember would not be necessary. The interengageable flanges are spacedsufficiently apart as denoted by F_(s), such that they may be positionedabove the interconnectable ends of a given forming member and lowered(as indicated by the arrows designated with an “A” in FIG. 10) andconnected with the interconnectable ends of the forming member. Forexample, in one embodiment, end panel 272 would have a length equivalentto the width denoted as P_(w) of forming member 10 (as shown in FIGS. 2and 1). The interengageable flanges 284A, 284B and 286A, 286B of endpanel 272 are adapted to be positioned above the interconnectable ends18 and 30 respectively of forming member 10 as shown in FlG. 1; theinterengageable flanges, then may be lowered down slidably over theinterconnectable ends 18, 30. That is, a user would lower and slide theinterengageable flanges 284A, 284B and 286A, 286B over theinterconnectable ends 18, 30 (being slotted or unslotted) of formingmember 10—and in place—so as to close off the passageway 16 of formingmember 10.

Now turning again to FIG. 11, other features of the spacer connector andforming system should also be recognized. The forming member isadvantageously configurable such that a given spacer element may beadapted to be selectively sized in relation to a desired form object. Aform object may include any of a number of structures used in buildingconstruction, for example, to form out a window opening, doorway, crawlspace, air space, or other opening or cavity before filling thepassageways of a formed up wall with concrete or the like (e.g., boards,pre-made box forms, pipes (e.g., for plumbing or wiring), etc). Such afeature may also be used to form archways, curved or angular headers, orany of a number of openings within a wall.

The form object 89 in FIG. 11 may preferably be a wooden board (such asa 2×4, 2×6, 2×8, etc.) having a width which is equivalent to the lengthof the selectively sized spacer element 91B. For example, the spacerelement may have a length equivalent to the passageway width as denotedby P_(w) as shown in FIG. 3, which would preferably be substantially thesame as the width of the form object 89. In this way, the at least twopanels 97A, 97B may be releaseably connected so as to removeably capturea desired form object 89 within the passageway 95. It should be furtherrecognized that, in one embodiment, the conformable material comprisesconcrete and the form object may comprise one or more form boards whichmay be connectable in a desired configuration and be selectively sized.That is, a window or doorway opening, or other void, cavity or the likecould be formed up by four 2×4 form boards connected to create thedesired shape (e.g., square, rectangle, etc.) and having a dimensionedperimeter and lateral width corresponding to the required window ordoorway opening dimensions. The form object could then be positioned ina desired location within the formed up passageway.

It should be noted that the formed up wall may include manyinterconnected and stacked forming members (e.g., shown in part in FIG.5) or any number of a plurality of forming members. In this way, theformed up wall of forming members would be adapted to “nest” the formboards within the passageway so as to form a desired cavity within thepassageway. Adjustable spacer connectors, may be positioned within thepassageway as desired and be sufficiently tightened around the formobject (e.g., to “squeeze off” the interface between the panel and formobject and create a seal) so as to prevent unwanted leakage of concreteor the like into the cavity. After concrete has been poured into thepassageway and cured, the spacer connectors (e.g., 91A, etc.) could bedisconnected and the panels (e.g., 97A, 97B) could be removed—along withthe “form object”—leaving the required window, doorway or other openingformed in the concrete wall.

Referring now to FIG. 15, the forming system also preferably furthercomprises a support connector 295 having a portion insertable through aspacer element 296 captured within a formed wall 297. That is, thespacer element 296 would remain, in some embodiments, after a materialhas been poured and has hardened around spacer element 296 and after thepanels have been disconnected and removed. In one embodiment, thesupport connector 295 preferably comprises a fastener element and atleast one support element, wherein the at least one support element isadapted to be secured proximate at least one surface (e.g., firstsurface or second surface (e.g., which may be inner and outersurfaces)—or both surfaces with multiple support elements) of a formedwall. In a possible embodiment, the support connector 295 preferablycomprises a fastener element 298 and a support element 299, wherein thesupport element is adapted to be secured proximate an inner surface(e.g., inner 289) of a formed wall.

The support element 299 is, in some embodiments, preferably secured bythe fastener element immediately adjacent the inner surface of a formedwall. In this way, the support element, in one embodiment, can be usedinside a structure (such as, for example, an interior room, garage orother enclosure or wall) to support some interior object 293 (such asfor example shelving, flooring, etc.). The support element 299 ispreferably configured so as to form an aperture 299A through which aportion of the support connector 295 (such as for example, the shaft ofa bolt or other connector (or part of fastener element 298)) may beinserted. In addition, the head 287 of the connector 295 could also berounded-off or substantially flush-mounted, in some embodiments, withrespect to surface 291 as desired.

It should be noted that a support connector could also be configured foruse with a forming member. That is, the support element could be adaptedto be secured adjacent to an interior surface of a forming member panelto support an object or forming object (see FIG. 11) or structure withinthe passageway (for example, to form a cavity or the like within thepassageway, in some embodiments, in a similar manner as shown in FIG.11).

Also, in one embodiment, after the panels are disconnected from thecured and formed wall of concrete, any aperture or opening in the formedconcrete wall (or a selectively configured support element) may be usedto attach a support member adapted to secure bricks, siding, paneling,insulation or insulating systems or some decorative or functional wallsurface to the formed concrete wall. Openings could also be selectivelysized with a spacer element (in some embodiments, with the spacerelement being removable) and be selectively located such that wiring,plumbing, conduit, piping, other building systems or components or thelike could be disposed through the opening to provide a passageway ormeans for locating, installing, or passing such building components fromthe outside to the inside of a formed structure such as a concrete shed,garage, or other building structure. In addition, if the apertures arenot used, they may be sealed with suitable sealers, plugged or filledwith suitable material.

Referring now to FIGS. 12 and 13, in some embodiments, it will beappreciated that a forming member may also further comprise a contourmember being mountable within the passageway of the forming member.

For example, in FIG. 12, contour member 280 may be configured, in oneembodiment, so as to be mounted on the inner surface of, for example,panel 14. The spacer elements 46, 48 (FIG. 1) would be sized andconfigured so as to be selectively insertable (e.g., through contourmember apertures 284, 286) or have distal ends adapted to secure thecontour member 280 immediately adjacent the inner surface of panel 14.The contour member could have the same perimeter dimensions as panel 14or it could be dimensioned to cover a plurality of inner surfaces ofvarious panels.

A contour member may have any number of a variety of surface patterns,reliefs, or other configurations. For example, as shown in FIG. 12,contour member 280 may have projections 282A, 282B, etc., forming aninner contoured surface having a plurality of ridges. These ridges wouldface into the passageway (e.g., 16 in FIG. 1) and create (or imprint) acorresponding pattern on the resulting outer surface of, for example, aformed concrete wall. In the same way, in FIG. 13, contour member 288 isshown having a raised star configuration 290 being mountable (e.g., viaapertures 292, 294) within a passageway in a similar manner as contourmember 280. Each of the contour members preferably has a selectedsurface contour facing the interior of the passageway.

With the design flexibility and configurability of the forming system, avariety of forming members having substantially linear and non-linearconfigurations (with inner and/or outer panels having any of a number ofdesign and visual features) could be interconnected to form up a wallhaving various designs, shapes, outer and inner wall surface contours,and dimensions.

In view of the foregoing, it should be noted that, the variousinterconnecting, stacking, and other cooperative and interrelationsfeatures of the substantially linear and/or non-linear forming membersprovides a forming system and method and apparatus such that a pluralityof forming members are selectively configurable and interconnectable inany of many desired arrangements. As such, at least a portion of anenclosure (e.g., a shed, garage, wall (e.g., see FIG. 5) or otherstructure to be formed with or without formed up windows, doors, orother features as explained hereinafter) may be constructed from theforming members, with the forming members defining a plurality ofpassageways for retaining a material which is, in one exampleembodiment, a conformable material such as concrete.

In use, the number of forming members, end panels, and other formingstructures to be made ready for a particular project will generallydepend on a pre-determined construction plan or blueprint or otherbuilding or structural layout. Typically, the dimensions of thebuilding, wall or structure will determine the number of forming membersneeded for the project. Each of preferably a plurality of formingmembers and/or panels (e.g., linear and/or non-linear forming members,end forming members and/or end panels, etc., as needed) may be assembledin a similar manner as that described herein (e.g., as explained foreach of the forming members, panels and structures with respect to FIGS.1-15).

For example, a linear forming member similar to forming member 10 (andother forming members), in one embodiment, is preferably assembled usinga desired selected spacer connector—which has a variable-length feature.That is, a spacer connector can be used which has a spacer element andconnector having a selected length depending on the desired “finished”wall thickness (which should be indicated in, for example, a buildingplan). As an example, the panels 12, 14 of forming member 10 arepreferably assembled and secured together with the selected spacerconnector in the manner as described above with respect to FIGS. 2 and3.

In one embodiment of a method, initially the base or ground levelforming members are placed first—with additional layers stackedthereafter. Corner-shaped forming members (e.g., like forming member 172in FIG. 7) or other forming members (or, for example, other non-linearforming members 230, etc.) are first preferably positioned according tothe building plan. The forming members are positioned and lined uppreferably level with the corner forming members so as to form a base orfooting of forming members (e.g., to form up the base perimeter of thestructure).

For example, with a forming member (e.g., 10) preferably positioned on adesired surface which is preferably flat and level, another formingmember (e.g., such as forming member 78, see FIG. 5) in one embodiment,is positioned immediately adjacent forming member 10. Generally, all ofthe forming members along the base or ground level (or footing) wouldhave the same width.

Preferably, the entire perimeter of forming members creating the base orground level is laid out and interconnected, in one embodiment, withengagement members (e.g. 68, etc. in FIGS. 4 and 5) (or, in someembodiments, a suitably configured slotted exterior angle). This processwill align the base or ground level perimeter to conform to the outlineof the building, wall, or structure.

The perimeter of forming members is preferably leveled, squared up andmade plumb as needed, by checking the horizontal and vertical alignmentand positioning using a common level tool or certain conventionalleveling equipment, shims or other systems and devices. Although it ispreferable that the forming members be interconnected and stacked in alevel row, the forming members may not be level in certain situations.In such instances, sometimes the fluidity of a poured conformablematerial such as, for example, concrete will generally level itselfwithin the formed up wall (which effectively forms a plurality ofpassageways or channels in communication with one another).

In one embodiment, for example referring to FIGS. 1-5, to interconnectadjacent forming members, engagement member 68 is positioned (asoriented in FIG. 4) above the interconnectable ends 20, 77 of theforming members and lowered into the slot 28 of forming member 10 andthe corresponding slot (not shown) of forming member 78 so as tointerconnect the two forming members. Forming member 156, preferablyhaving the same (or similar) configuration as forming member 10, is thenpreferably stacked on forming member 10 (as shown). That is, the baseflanges 104, 106 of forming member 156 are lowered between the supportmembers 96, 100 (see FIGS. 1 and 5) of forming member 10 so as to bealignably received and secured between the support members (e.g., inthis way, forming member 156 rests or sits on top of forming member 10).A pin (e.g., 154 in FIG. 14) may also be inserted into correspondingapertures in the base flanges of forming member 156 and preferablyhorizontally oriented guide flanges of the support members 96, 100. Inthis way, the stacked forming member 156 may be more securely alignedwith forming member 10. In addition, concrete nails, spikes, or othersuitable anchoring devices may be used to secure the base flanges offorming members 10, 78, 218, etc., to a desired surface or the ground.Other forming members (e.g., having substantially linear configurations(e.g., straight or end forming members or panels, etc.) or substantiallynon-linear configurations (e.g., 90-degrees; 45-degrees; T-shapedforming members, etc.) may be interconnected and stacked in a similarmanner to build a formed up wall (as shown FIG. 5 (not showing cornerforming members, etc.)), enclosure, or other structure.

In some structures, it is at the base level that interior formingobjects and the like are placed in the passageways (inside the formingmembers). That is, as explained before, form objects (form boards,boxes, pipes, etc.) may be installed within the passageways to createvoids for window or doorway openings, holes for piping or plumbing(e.g., at the base or ground level) or other cavities. Forming objectsfor windows are placed at the level needed when forming up a wall.

Also, the formed up wall may be reinforced using steel rods or rebar orother structural reinforcements. Rebar, for example, may be positionedand oriented as desired (horizontally, vertically, diagonally, etc.)within the passageways or channels and tied or wired to spacer elementsor just, in some appropriate instances, positioned in place as desired.Reinforcing structures secured vertically aid in joining each level offorming members and keeping the forming member rigid and in place.Bracing structures (e.g., boards, tension wires, cables, etc.) may alsobe installed or secured as needed. Moreover, other structures,connectors (e.g., such as J-anchors, anchor bolts, etc.) or the like,may be used in some instances (e.g., on top form rows) to attach, tie inor anchor a roof to a wall (or to tie a wall to an existing wall) or thelike. The base (or ground) level may then receive concrete, oradditional forming members may be stacked in the same conformity as thebase level as noted herein. This process may be continued to the desiredheight of the wall. With this configuration, concrete may be poured in aone-pour process (or level-by-level as will be explained further.) (Itshould be noted that sometimes it might also be desirable toappropriately—and very carefully—vibrate or agitate the wet concrete tocause it to fill voids and flow more evenly throughout the passageway).

After the wall has been completely poured and has cured, the formingmembers and forming objects may be removed and the desired openings forwindows, doors, plumbing, etc., will remain. Also, after removing theconnectors and panels, the spacer elements will remain leaving openingsthat may be used (depending on what is built) or that may be filled witha sealer, foam, or concrete or plugged as noted earlier.

As noted above, with the modular, compact, and removable configurationof the forming members and system, a wall or structure could be built inone or more layers, levels, sections or stages at a time—as isconvenient for the user. (It should also be recognized that with such aconfiguration, only the spacer element, in some embodiments, isgenerally not reusable).

For example, two rows of forming members could be formed up andreinforced with rebar, and then concrete could be poured. After theconcrete hardens, the same forming members could be dissembled and usedat a later time (e.g., over another weekend, etc.) to form up, tie inand pour another section of the wall. The same process could befollowed—or be stopped and started as convenient for the user—until thedesired building structure is completed. With such features, the formingsystem could readily be used, at a person's convenience, for example, ina person's backyard for weekend projects or the like.

In certain embodiments, it should be noted that the footings of wallsections (or the walls) could also have varying widths. For example, onefooting section could have a width of eight inches (e.g., to support awall of eight inches) and be connected to another footing section with awidth of ten inches (e.g., to support a wall of ten inches). Thus, forexample, in one embodiment, a selectively configured forming memberwould be provided and serve as an interface forming member to transitionbetween walls of varying widths. Such an interface forming member wouldbe configured such that each panel (e.g., modified panels 12, 14) wouldhave extensions bent outwardly at a desired location away from thepassageway (e.g. 16). Each of the panel extensions would extendsufficiently such that the interconnectable ends and slotted elementswould be lined up and be interengageable with the interconnectable endsand slotted elements of the wider forming member. For example, panelextensions would be added to the eight-inch wide form so as to positionand line up the interconnectable ends and slotted elements thereof suchthat they would be interengageable with the correspondinginterconnectable ends and slotted elements of the wider ten-inch formingmember—and be connectable with an engagement member (e.g., 68). In thisway, an appropriate structural interface would be established betweenadjacent formed up walls with different widths.

Referring again to FIG. 1, in one possible embodiment, each panel 12, 14may preferably be sized, for example, to be about one foot high and twofeet long. It should be recognized that each forming member (e.g.,substantially linear, non-linear, etc.) may be uniformly or universallysized and interconnectable. In other embodiments, however, one panel mayhave a different size than its complementary panel. Various panels orforming members may have different sizes or shapes and be connected inspaced relation to create any of a number of formed wall designs andconfigurations. For example, the forming member could be configured as afirst level forming member and adapted to be placed directly on astepped region of a footing, foundation, sidewalk, walkway, street,curb, or some platform-like structure. That is, the panels would beshaped such that the body (e.g., 13 in FIG. 1) of the panel and baseflanges would be formed or constructed so as to have a steppedconfiguration (e.g., or a variable shaped bottom flange or edge) that iscomplementary and in functional cooperation with the stepped surfaces orthe like (or other surfaces). In this way, a wall could be formed up anddirectly poured on an irregular surface or foundation or other existingstructure. The wall could be secured to or tied into the existingstructure by interconnecting rebar or other components to the formingmember (e.g., spacer element) and then to some anchoring component ormember on the existing structure.

In addition, the panels are preferably connected with two uniformlyconfigured spacer connectors. In other possible embodiments, however,each panel may be much larger or smaller and the number of spacerconnectors can be increased or reduced as suitable.

It will be appreciated that a given forming member (e.g., 10, 172, 310,230, etc.) may be used in certain situations without any spacerconnectors. This is because, in a possible embodiment, as noted, aforming member (for example, 10, 172) has a pair of interconnectableends (e.g., 18, 30 and 20, 32), at both ends (e.g., 180, 182),respectively, of the forming member (e.g., 10). Each of the ends 180,182 of forming member 10 is adapted to be interconnected tocomplementary ends of adjacent forms. The interconnection with theadjacent forms, in some instances, may be sufficiently tight and firm tohold the panels of a given forming member in spaced relation without theneed for having to install spacer members, connectors, standoffs, etc.,to maintain the desired spacing.

In another possible embodiment of the present invention, with somefeatures being similar, in one embodiment, to those in FIG. 1, a formingsystem to retain a material is provided. The forming system, in oneembodiment preferably comprises a forming member comprising at least twopanels in spaced relation so as to define a passageway adapted to retaina first supply of settable material. In such an embodiment, each of theat least two panels (e.g., in one embodiment, 12, 14) further comprisesa base flange (e.g. in one embodiment 94, 98) extending from each panelaway from a passageway of the forming member, and a support member (e.g.in one embodiment, 96 and 100) on an opposite side from the base flangewith the support member extending away from the passageway. The supportmember further comprises a guide member (e.g. in one embodiment, 110 and114) adapted to alignably receive a base flange of another formingmember when stacked on the forming member. In this way, the at least twopanels are alignable with at least two panels of another forming panel.In addition, the forming system may have a configuration wherein each ofthe support members further comprises a support flange and a guideflange with the guide flanges of the support members being disposed inopposing spaced relation. In one example embodiment, such aconfiguration is similar to that described above with respect to FIG. 1.

Moreover, each of the at least two panels (for example, items 12, 14 inone possible embodiment) of the forming system are adapted to bedisconnectable, after retaining the first supply of settable material tosubsequently receive a second supply of settable material.

The forming system also preferably further comprises a plurality offorming members with the plurality of stacked forming members defining awall of forming members defining a plurality of vertically-extendingpassageways for retaining a material. In one example embodiment, such aconfiguration is similar to that described above with respect to FIG. 1.

In addition, in another possible embodiment, the forming system may alsocomprise at least two panels wherein each of the at least two panelscomprises at least one interconnectable end defining a securable flange.The securable flange is preferably adapted to be interconnectable with acorresponding securable flange of another forming member. The formingsystem preferably further comprises an engagement component adapted tointerconnect a securable flange (which in some embodiments, may formapertures adapted to be interconnected with other securable flanges byengagement components such as fasteners, connectors or the like) (asnoted above and/or as noted in the embodiments explained hereinafter) ofthe forming member, with a corresponding securable flange of anotherforming member. It should be noted that in some embodiments thesecurable flanges may be slotted, however in other embodiments thesecurable flange may not be slotted. Moreover, in some embodiments, theengagement component may have a configuration similar to the engagementmember described in the various embodiments described above and asfollows; however, in other embodiments, the engagement component mayhave an unslotted configuration or some other different configurationadapted for securing the securable flange and corresponding securableflanges together. Such securing structures may comprise structures asdescribed earlier herein or hereinafter or they may comprise clamping orvice grip-like devices, threaded or unthreaded fasteners, as well asother suitable securing systems and devices known in the art.

In one other embodiment, the forming system comprises a forming membercomprising at least two panels in spaced relation so as to define apassageway adapted to retain a first supply of settable material. Insuch an embodiment, and in view of the interconnectable ends shown inFIG. 1, each of the at least two panels further comprises at least oneinterconnectable end defining an interconnectable element forming aninterengageable slot, similar, in one embodiment, to the configurationshown in FIG. 1 (e.g., item 18, etc.), with the interconnectable elementadapted to be interconnectable with at least one other forming member.The forming system preferably further comprises an engagement memberforming an interconnection slot, similar, in one embodiment, to thatshown in FIG. 4 (e.g., item 68, etc.), with the engagement memberreceivable by both an interengageable slot of an interconnectableelement of a given forming member and an interengageable slot of aninterconnectable element of the at least one other forming member. Withthese features, the given forming member and the at least one otherforming member may be interconnected and a plurality of forming membershaving selected configurations may be interconnected and stacked (e.g.,see FIG. 5, showing one possible embodiment).

With this configuration and in view of other various features as notedherein, a plurality of walls of forming members may be interconnected soas to form at least a portion of an enclosure. Such an enclosure may bea shed, well or pool house, garage, home or addition, wall, or otherbuilding structure.

The forming system, in another possible embodiment also preferablycomprises a forming member further comprising at least one spacerconnector comprising a spacer element and a reusable connector, with theat least one spacer connector adapted to releaseably connect the atleast two panels in spaced relation. The spacer connector and panels, inone example embodiment, have a configuration that is similar to thatdescribed above with respect to FIG. 1. In addition, the forming systemmay also comprise various forming members with the at least two panelshaving desired shapes and configurations so as to define a passagewayhaving a substantially non-linear configuration adapted to retain asettable material. In some embodiments, the at least two panels may beconfigured so as to define a passageway having a substantially 90-degreeconfiguration or a substantially T-shaped configuration as noted aboveadapted to retain a settable material.

In one other possible embodiment, the forming system may comprise analternate forming member configured such that a first end comprises apair of interconnectable ends 18, 30 (with or without slots) of aforming member 10 as shown in FIG. 1. However, the second end comprisesa pair of “flanged” interconnectable ends similar to the flangedinterconnectable ends 180, 182 shown in FIG. 10—and mounted at thedistal edges of panel 274.

With such a configuration, a pair of interconnectable ends 18, 30 of analternate forming member would not need a specially configuredinterconnectable element defining an interengageable slot (like thatshown in FIG. 1). With a configuration similar to that described withrespect to FIG. 10, the flanged interengageable ends 180, 182 mounted onthe second end of the alternate forming member would be adapted to bepositioned above the interconnectable ends 18 and 30 respectively of thefirst end of another alternate forming member. The flangedinterconnectable ends 180, 182 would then be slidable over—andconnectable with—the interconnectable ends 18, 30. In this way, a firstalternate forming member could be connected in place immediatelyadjacent to another similarly configured second alternate forming memberto continue a formed up passageway.

In addition, it will be appreciated that the above configuration isspecially configured such that the first and second ends of two adjacent“alternate” forming members may be interconnected—without the use of anengagement member.

In other words, in one possible embodiment, a forming member preferablycomprises a first end which comprises a pair of interconnectable ends,ears or securable flanges (e.g., configured similar to 18, 30 of formingmember 10 but without defining any interengageable slots), protrudingaway from the passageway and being disposed substantially orthogonallywith respect to its panel. The second end of the forming member maycomprise a pair of different but corresponding flanged interconnectableends (configured somewhat similar to flanged interconnectable end 280(shown in FIG. 10), comprising a similar pair of spaced interengageableflanges 284A, 284B and configured somewhat similar to flangedinterconnectable end 282 comprising a similar pair of spacedinterengageable flanges 286A, 286B). On each panel of the formingmember, each of the corresponding flanged interconnectable ends may bedisposed so as to preferably protrude substantially orthogonally awayfrom the passageway and its respective panel. With this alternateconfiguration, corresponding flanged interconnectable end (similar to280) preferably comprises a pair of spaced interengageable flanges(similar to 284A, 284B) and corresponding flanged interconnectable end(similar to 282) preferably comprises a pair of spaced interengageableflanges (similar to 286A, 286B)—mounted on a forming member rather thanan end panel (e.g., 272). In a similar manner as described with respectto FIGS. 1 and 10 (and in one embodiment similar to the “alternate”forming members above) it will be appreciated that the interengageableflanges are specially configured such that they may be interconnected tothe interconnectable ends of an adjacent forming member—without the useof an engagement member. That is, a forming member with thisconfiguration, has a first end with interconnectable ends similar tothose shown in FIG. 1 (e.g., 18, 30) and a second end with correspondingflanged interconnectable ends similar to those shown in FIG. 10 (e.g.,280, 282). In addition, the first or second ends could be offset orangled or mounted in such a way as to foster a tighter connectionbetween the adjacent forming members.

Thus, in view of the versatility and configurability of the formingmember, in a possible embodiment, forming member 10 may include at leastone but preferably two interconnectable ends with each interconnectableend defining a securable element or flange—with or without a slottedconfiguration. However, in another example embodiment, each of thesecurable elements, may, for instance, define, form, and/or comprise aninterengageable slot, respectively or other securable structure. Eachinterconnectable end may also define a securable flange or other elementand each of the securable elements, in one example embodiment, may, forinstance, define, form, and/or comprise an interengageable slotrespectively.

In one other possible embodiment, a forming member comprises at leasttwo reusable panels with each panel being of one-piece constructioncomprising at least one of sheet metal or plastic. The forming memberfurther preferably comprises at least one spacer connector (in oneembodiment, similar to that described with respect to FIG. 1) comprisinga spacer element and a connector with the at least one spacer connectoradapted to releaseably connect the at least two reusable panels inspaced relation so as to define a passageway. Each of the at least tworeusable panels preferably also comprises at least one interconnectableend adapted to be interconnectable with a securable flange of anotherforming member. The interconnectability of various such forming membersmay, in some example embodiments, have interconnectable ends configuredin the same manner as those described with respect to FIG. 1 (or asother embodiments herein). In addition, in one other embodiment, each ofthe at least two reusable panels further comprises a base flange and asupport member. (In some embodiments, the support member of the formingmember is preferably adapted to alignably receive a base flange ofanother forming member, if stacked on the forming member). Moreover, insuch an embodiment, each of the at least two panels, the at least oneinterconnectable end defining a securable flange, the base flange, andthe support member are integrally formed from a unitary structure. (Insome embodiments, such a unitary structure may be similar to thatdescribed with respect to FIG. 6C above). In another possibleembodiment, the forming member also may further comprise at least onespacer connector with at least one corresponding aperture formed in theunitary structure for receiving at least a portion of the spacerconnector. The spacer connector may also comprise a spacer element and areusable connector with the reusable connector comprising a threadedfastener tightenable by hand. (Such an embodiment may be similar to thatdescribed with respect to other forming members herein).

Referring now to FIGS. 1, 2, 5-11 and 14, it will also be appreciatedthat the apertures formed in the various panels may be located at anydesired position such that the spacer connectors may be selectivelyinstalled within a given passageway (e.g., 16, 316, 178, 238) at anydesired location. For example, it may advantageous to locate the spacerconnectors near the top of a forming member so that it could be used toaid in supporting or anchoring or securing some structure.

In addition, in some embodiments, the panels may form only a singlecomplementary pair of apertures to accommodate only one selectivelylocated spacer connector. As noted above, in other example embodiments,a pair of panels may not have any apertures formed therein and thepanels may be held in spaced relation when interconnected to an adjacentforming member being secured in spaced relation by spacer connectors (orend forming members or end panels). For example, spacer connectors mayonly be installed in every other interconnected forming member.

The foregoing disclosure and description of the invention isillustrative and explanatory of presently preferred embodiments of theinvention and variations thereof, and it will be appreciated by thoseskilled in the art, that various changes in the design, organization,order of operation, means of operation, equipment structures andlocation, methodology, the use of mechanical equivalents, such asdifferent types of spacer connector components, spacer devices, adjacentforming member connectors than as illustrated whereby different stepsmay be utilized, as well as in the details of the illustratedconstruction or combinations of features of the various elements may bemade without departing from the spirit of the invention. As well, thedrawings are intended to describe the concepts of the invention so thatthe presently preferred embodiments of the invention will be plainlydisclosed to one of skill in the art but are not intended to bemanufacturing level drawings or renditions of final products and mayinclude simplified conceptual views as desired for easier and quickerunderstanding or explanation of the invention. As well, the relativesize and arrangement of the components may be varied from that shown andthe invention still operate well within the spirit of the invention asdescribed hereinbefore and in the appended claims. Thus, various changesand alternatives may be used that are contained within the spirit of theinvention.

Because many varying and different embodiments may be made within thescope of the inventive concept(s) herein taught, and because manymodifications may be made in the embodiment(s) herein detailed inaccordance with the descriptive requirements of the law, it is to beunderstood that the details herein are to be interpreted as illustrativeof a presently preferred embodiment and not in a limiting sense.

1. An apparatus for retaining a conformable material, the apparatuscomprising: a forming member comprising at least two panels connected inspaced relation so as to define a passageway adapted to retain a firstsupply of conformable material, which hardens in place; wherein each ofthe at least two panels further comprises at least one interconnectableend defining an interconnectable element forming an interengageableslot, the interconnectable element adapted to be interconnectable withat least one other structure; and wherein the at least two panels areadapted to be disconnectable after use to subsequently receive a secondsupply of conformable material, which hardens in place.
 2. The apparatusof claim 1, wherein the at least one other structure comprises at leastone other forming member, and further comprising an engagement memberforming an interconnection slot, the engagement member receivable byboth an interengageable slot of an interconnectable element of a givenforming member and an interengageable slot of an interconnectableelement of the at least one other forming member, wherein the givenforming member and the at least one other forming member may beinterconnected.
 3. The apparatus of claim 2, wherein a plurality offorming members are selectively configurable and interconnectable in adesired arrangement, and wherein at least a portion of an enclosure maybe constructed from the forming members, the forming members defining aplurality of passageways for retaining the conformable material.
 4. Theapparatus of claim 1, wherein each of the at least two panels furthercomprises a base flange and a support member.
 5. The apparatus of claim4, wherein the at least one other structure comprises at least one otherforming member, wherein the support members of a given forming membercooperate to alignably receive the base flanges of the at least oneother forming member when stacked on the given forming member, andwherein a plurality of stacked forming members would define a wall offorming members defining a plurality of vertically-extending passagewaysto retain the conformable material.
 6. The apparatus of claim 5, whereineach of the support members further comprises a support flange and aguide flange, the guide flanges of the support members being disposed inopposing spaced relation.
 7. The apparatus of claim 4, wherein eachsupport member is disposed at least in part proximate a top edge of arespective panel with each support member being oriented substantiallyorthogonal with respect to the panel so as to reinforce the panel. 8.The apparatus of claim 1, wherein the forming member further comprisesat least one spacer connector comprising a spacer element and a reusableconnector, the at least one spacer connector adapted to releaseablyconnect the at least two panels in spaced relation.
 9. The apparatus ofclaim 8, wherein the spacer element is adapted to be selectively sizedin relation to a desired form object, wherein the at least two panelsmay be releaseably connected so as to removeably capture a desired formobject within the passageway.
 10. The apparatus of claim 1, wherein theat least two panels are configured so as to define a passageway having asubstantially non-linear configuration adapted to retain a conformablematerial.
 11. The apparatus of claim 1, wherein at least three panelsare configured so as to define a passageway having a substantiallyT-shaped configuration adapted to retain a conformable material.
 12. Theapparatus of claim 1, further comprising a contour member beingmountable within the passageway, the contour member having a selectedsurface contour facing the interior of the passageway.
 13. A formingsystem for retaining a material, the forming system comprising: aforming member comprising at least two panels in spaced relation so asto define a passageway adapted to retain a first supply of settablematerial; wherein each of the at least two panels further comprises abase flange extending from each panel away from the passageway, and asupport member on an opposite side from the base flange, the supportmember extending away from the passageway, wherein the support memberfurther comprises a guide member adapted to alignably receive a baseflange of another forming member when stacked on the forming member,wherein the at least two panels are alignable with at least two panelsof said another forming panel; and wherein the at least two panels areadapted to be disconnectable after retaining the first supply ofsettable material to subsequently receive a second supply of settablematerial.
 14. The forming system of claim 13, wherein each of the atleast two panels comprises at least one interconnectable end defining asecurable flange, the securable flange adapted to be interconnectablewith a corresponding securable flange of another forming member, andfurther comprising an engagement component adapted to interconnect asecurable flange of the forming member, with a corresponding securableflange of another forming member.
 15. The forming system of claim 13,wherein each of the at least two panels further comprises at least oneinterconnectable end defining an interconnectable element forming aninterengageable slot, the interconnectable element adapted to beinterconnectable with at least one other forming member, and furthercomprising an engagement member forming an interconnection slot, theengagement member receivable by both an interengageable slot of aninterconnectable element of a given forming member and aninterengageable slot of an interconnectable element of the at least oneother forming member, wherein the given forming member and the at leastone other forming member may be interconnected, wherein a plurality offorming members having selected configurations that may beinterconnected and stacked, and wherein a plurality of walls of formingmembers may be interconnected so as to form at least a portion of anenclosure.
 16. The forming system of claim 15, and further comprising atleast one spacer connector comprising a spacer element and a reusableconnector, the at least one spacer connector adapted to releaseablyconnect in spaced relation each of the at least two panels of at leastone of the forming members.
 17. The forming system of claim 13, whereinthe at least two panels are configured so as to define a passagewayhaving a substantially non-linear configuration adapted to retain asettable material.
 18. The forming system of claim 13, wherein at leastthree panels are configured so as to define a passageway having asubstantially T-shaped configuration adapted to retain a settablematerial.
 19. The apparatus of claim 13, further comprising a supportconnector having a portion insertable through a spacer element capturedwithin a formed wall, the support connector comprising a fastenerelement and at least one support element, wherein the at least onesupport element is adapted to be secured proximate at least one surfaceof a formed wall.
 20. A unitary structure reusably combinable with otherunitary structures to create forms to receive settable material, whichcomprises: a panel; at least one integrally formed interconnectable enddefining a securable element; a base flange integrally formed at a firstperipheral edge of the panel; and a support member integrally formed ata second peripheral edge of the panel, the panel, at least oneintegrally formed interconnectable end, base flange, and support memberbeing of one-piece construction and comprising at least one of sheetmetal or plastic.